TERRA WALKER DRILLING

Safety Alert
 Hindustan Zinc Limited
Unit: CLZS – Hydro 1 Cell House

An HIPO Incident occurred at CLZS…..

On 16.04.2019, during heavy rains and very high wind velocity (storm), the WI-FI tower installed on IT office
roof top, of height 24 meters collapsed & fell on the Cell house road in front of IT office. As a precautionary
measure and awareness to remain indoors during the storm, nobody was in vicinity of that area, no injury.

KEY LEARNINGS:

1) Tall structure design must be mapped by competent person and life cycle to be defined. The design
should take in consideration the very high wind velocities
2) Structural stability of high towers & buildings should be assessed periodically by competent person.
3) Proper support should be provided to very high towers and buildings.
4) During storm / heavy rain nobody should be allowed to work at open places / nearby high towers and
building.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Date- 23-04-2019

Terra Walker Drilling pvt. Ltd Alert Discussion

Safety Alert सुरक्षा चेतावनी

Topic ववषय
Wi-fi Tower collapse वाई-फाई टॉवर का गिरना

Alert Description: -
On 16.04.2019, during heavy rains and very high wind velocity (storm), the
WI-FI tower installed on IT office roof top, of height 24 meters collapsed &
fell on the Cell house road in front of IT office. As a precautionary measure
and awareness to remain indoors during the storm, nobody was in vicinity of
that area, no injury.
चेतावनी वववरण: -
16.04.2019 को, भारी बाररश और बहुत तेज़ हवा के वेि (तूफान) के दौरान, आईटी कार्ाा लर् की
छत के शीर्ा पर स्थागपत WI-FI टॉवर, ऊंचाई 24 मीटर ढह िई और IT कार्ाा लर् के सामने से ल
हाउस रोड पर गिर िई।
र्ह एक एहगतर्ाती उपार् और तूफान के दौरान घर के अंदर रहने के गलए जािरूकता के गलए है ।
कोई भी उस क्षेत्र के आसपास नहीं था, कोई चोट नहीं थी।
KEY LEARNINGS:
1) Tall structure design must be mapped by competent person and life cycle
to be defined. The design should take in consideration the very high wind
velocities
2) Structural stability of high towers & buildings should be assessed
periodically by competent person.
3) Proper support should be provided to very high towers and buildings.
4) During storm / heavy rain nobody should be allowed to work at open
places / nearby high towers and building.
मुख्य सीख:
1) लं बा संरचना गडजाइन सक्षम व्यक्ति द्वारा मै प गकर्ा जाना चागहए और जीवन चक्र को पररभागर्त गकर्ा जाना
चागहए। गडजाइन को बहुत उच्च वार्ु वेिों को ध्यान में रखना चागहए

2) उच्च मीनारों और इमारतों की संरचनात्मक क्तस्थरता का आकलन समर्-समर् पर सक्षम व्यक्ति द्वारा गकर्ा
जाना चागहए।
3) बहुत ऊंचे टावरों और इमारतों को उगचत समथा न प्रदान गकर्ा जाना चागहए।

4) तूफान / भारी बाररश के दौरान गकसी को भी खुले स्थानों / आस-पास के ऊंचे टावरों और भवन में काम
करने की अनु मगत नहीं दी जानी चागहए।
 Hindustan Zinc Limited
Unit: SKM

A Fatal Incident occurred at SKM

On 9th April 2019, at around 8:20 AM while an operator of M/s. Reliant was reversing the mine truck (LPDT MT-
65, No.5) at North ramp parking yard, the front left tyre (operator cabin side) rolled over the IP of Epiroc causing
crush injury. After recovering IP from the position, he was immediately taken to Dariba Zinc Hospital, where he
succumbed to the Injury. Detail investigation is under progress.

Initial & Final Position of trucks which moved out of parking position
Learning for immediate implementation:

1. No person shall walk near any moving equipment and also stay away from the stationary equipment.
2. All vehicles must be parked at designated parking place only. No person other than operators shall be
allowed to be in parking area during the movement of equipment.
3. All HEMM/ vehicles shall be parked in reverse parking mode only.
4. Any Maintenance activities shall not be allowed during equipment movement (shift start & end)
5. Before starting the machine, a walk around inspection and checking of blind spot mirrors/cameras is
mandatory.
6. Before moving the equipment, a warning by blowing horn minimum twice with a time interval shall be
given by the operator.
7. All operators, maintenance team, mining workforce to be made aware of hazards, blind spots.
8. Maintenance activities to be performed after a LOTO and battery cut off
9. Pedestrian walkways must be provided in all parking areas/ machine movement areas to avoid Man-
machine interaction.
 Hindustan Zinc Limited
Unit: DSC

LTI Incident Occurred at DSC Zinc

On 03.04.2019 at 1550 hrs , Roaster R5 start up activity was in progress, Control Room Operator started the
ACT 53 Return Water Pump, after it started, the IP went to open the discharge valve, after opening the valve,
while moving to go to ACT 53 area, Suddenly the H support of the return waetr pump discharge pipe line
installed at a height of 8m fell on the Hydrojet Machine Electrical Panel at ground floor and then hit the IP on
the helmet and also impacted on the left shoulder, IP was sent to Hospital for examination, where after X-ray
a Hair line fracture at Clavicle collar bone was found. IP has been referred to Hospital at Udaipur for further
treatment.

Detailed investigation in progress

KEY LEARNINGS:

1. Support installed which are subbjected to vibrations specially for high capacity pump discharge line to
be checked and to be part of PM list for structure check at scheduled frequency.
2. The support design to be looked into for improvements and standardisation across plants.
3. Audit of all pipe racks to identify nonstandard support installed and removal of nonstandard and
temporary support
4. Awareness improvement in all personnel for reporting of such process abnormality of water
hammering and vibration in pipe line/structure.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 SAFETY ALERT #99

Struck by Moving Locomotive – Fatal incident at KCM, Konkola U/G mines

Re-enactment: location of worker Simulation of pin used to couple cars

On March 20, 2019, Mr. James Katai, the Person in Charge of Tramming for Business Partner MMS,
was fatally injured when he was struck on the head by a moving rail car in Bancroft Deeps. Mr. Katai
was uncoupling two cars attached to a locomotive and at the same time the loco driver was moving
the train backward and forward to dislodge rocks from a blocked track.
Mr. Katai was aged 49 and is survived by his wife, two sons aged 22 and 19 and daughter aged 15.
All businesses are required to immediately ensure:
• Key leaders such as Underground Mine Managers provide adequate oversight that work crews have
effective team management and communication in place; and that they comply with correct operating
practices
• Training and SOPs are in place for rail operations, including locomotive driving, re-railing locomotives
and rail cars, loading cars at chute boxes, tramming and coupling/decoupling
• Employees use a coupling hook for removing pins when decoupling rail cars
• Locos and rail cars are stopped, chocked and the Whistleman standing 1 meter away when any person
enters the footprint of a rail car or locomotive
• Rail equipment is used for its designed purpose only
• Risk assessments are developed and reviewed with all workers for tramming, loading and dumping
operations
• Automated coupling and decoupling systems are reviewed and considered for implementation where
possible

Phil Turner
Group Head HSE & Sustainability
 Hindustan Zinc Limited
Zawar Mines

An MTI Incident Occurred at Zawar Project site…

On 03.04.19 at 14:20 hrs, an employee of M/s. Alpha Engineering & services was working at FOB floor for
core cutting of Cardox nozzle. During the core cutting work IP moved backward and stepped on the grating
which got dislodged from its position. IP got imbalanced and fell through the opening created from
dislodging of grating from one level to another (approx. 3 mtr. Height). IP got a minor cut injury behind
his left ear. Immediately First aid given at Zawar hospital and sent the IP to Udaipur for precautionary
detailed investigations. Full body X-ray & CT scan done & found normal.

KEY LEARNING:

1. All platforms/gratings to be checked before working in elevated location for their proper fitment.
2. An inspection schedule to be created and followed for checking the gratings, stairs, railings etc.
3. Thorough inspection of work area to be done by job supervisor before commencing any job and a risk
assessment to be done

PLEASE SEE AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE
 Hindustan Zinc Limited
Unit: PMP Zinc

A MTI occurred at Pantnagar Zinc plant

On date 26.03.2019 at around 10:30 AM, IP was engaged to remove Furnace-01 gate for drossing work. Gate
is having two pins for proper locking, first pin was removed & IP was trying to remove the second pin when
suddenly gate fell on right hand. IP was wearing all required PPEs so no burn injury but due to caught in
between, impression on right thumb bone diagnosed.

IPs Position (Representative picture)

Key Learning:

1. Furnace gate to be modified and repaired for easy operation. Automation of the gate opening / closing
to be implemented.
2. SOP/WI for door opening and closing to be reviewed.
3. While performing the job, Line of fire to be assessed for each activity.
4. Maintain approach area obstacle free and clean.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: Zawar Mines, Mill

LTI- RWI Incident occurred at Zawar Mines

On 22.03.2019 at 11:30 AM in Crusher Store Room, the maintenance of Reciprocating feeder was in progress
at Balaria crusher. During maintenance trunnion replacement was required. The IP was sent to Crusher store
to get the material. While lifting the trunnion by hand from improperly stacked heap of material, the trunnion
slipped and fell on right palm of IP. He felt some pain and was immediately send to HZL Hospital, Zawar
Mines. After first aid he was referred to Udaipur for further treatment. In the X-Ray he was diagnosed with
hair line fracture.

KEY LEARNING:

1. Proper stacking of the material shall be ensured at the workplace. The housekeeping to be improved
2. Material handling to be done after a proper risk assessment.
3. Job specific personal protective equipment must be worn.

IT MUST BE ENSURED THAT NO SUCH ACTIVITY TAKES PLACE AT YOUR SITE

 Hindustan Zinc Limited
Unit: Kayad Mines

An HIPO incident occurred…

On 19.06.2017 at 1:30 PM in ‘A’ shift, LMV parked by Atlas technician at S 175 mrl S DSP and he went
to check the machine inside the NOD of same level. Mucking was planned in South decline 150 mrl
face and loader operator was dumping the muck inside the same DSP before parking of the LMV
about which the LMV operator was not aware of. The loader operator went inside the DSP x cut, and
started dumping. On hearing some some noise, he immediately stopped. When checked, he found
the LMV parked there and got damaged condition. No person was there. No injury.

The detail investigation is in progress.

Loader 17 T

LMV

KEY LEARNING:

1. No equipment should be parked at a non-designated place.

2. In active loading/ dumping area no LMV should enter. The SOP to be revised.
3. Possibility to be explored for Beacon lights to be integrated with battery so that it can work even
after ignition is off.
4. Standardize fitment of front view camera in all loaders.
5. Provision of active loading signage in mucking levels. Explore putting portable flashing light in
active dumping area before start.

ENSURE THAT SUCH INCIDENT SHOULD NOT HAPPEN AT YOUR SITE.

 Hindustan Zinc Limited
Unit: Kayad Mine
Location: 275 mRL South section

An Injury incident occurred 

On 8th April-15, in B shift, around 19.15 hrs, after completion of pipeline work at 275 mRL South Section, the
operator of N2 Scissor lift, who was carrying rock bolt testing machine came at 275 mRL passing bay to place
it in N-1 Scissor lift. The operator of N-1 parked scissor lift was behind the N-2 in same passing bay for
collecting the rock bolt testing machine. N-2 Scissor lift engine was in running condition. Two persons were
engaged in shifting the rock bolt testing machine. One person was standing on the lift of N-2 and IP was
standing near N-2 on ground. The operator of N-1 gave signal to N-2 operator to shift forward. Without
noticing the unloading work under progress N-2 operator moved forward. IP was standing very close to N-2
due to which wheel slightly rolled over IP’s right foot and IP fell down. IP was given first aid in u/g and
brought to surface then sent to Hospital.

KEY LEARNINGS:
• The Operator did not follow the SOP while movement of Scissor lifts.
• While loading or unloading the material vehicle should be in off condition.
• Communication gap between the supervisor and employees.
 Hindustan Zinc Limited
Unit –CLZS -Pyro

A person was injured (LTI)

An LTI occurred in ISF plant met coke yard on 10th Nov, 2014 in which a contract employee got injured. At
around 14:45 hrs. Auto Garage fitter with his helper (I.P) came to coke yard for weekly check-up &
repositioning of head lights of JCB Loader no.5. After verbal permission from JCB Loader operator they started
their job on the loader. First they fixed the right side head lights & then I.P. was doing electrical wiring of left
side head light at around 15.35 hrs.

At around 15:40 hrs. Coke truck unloading hydra operator called Loader operator for pushing of coke for
further unloading of next truck. Operator looked in surrounding for Auto garage fitter but he did not see him &
he assumed that work of auto garage people finished their job & went off. He entered in loader from left gate
which was in open condition & could not see the I.P. who was working behind left gate. He started the loader
with key which was already in ignition position (for keeping lights on), took the loader slightly in reverse
direction same time, heard some screaming and stopped the loader. He noticed that I.P was entrapped
between left front tyre & its mud guard, immediately he took the loader forward & took out the I.P., who was
then taken to plant dispensary by auto garage people.

X-Ray revealed minor cracks in the back bone. He has been sent to GBH American Hospital, Udaipur and is
under medical surveillance. Further investigation revealed Loader operator was under the influence of alcohol.

Site Photograph:

Position of I.P.

KEY LEARNINGS:-

1) Ensure that no person work under the influence of alcohol or drugs

2) Ensure Risk assessment is done before starting such non-routine activities & PTW to be followed
3) Ensure that Key handover take over system shall be followed.
4) Ensure Standard wheel choke shall be used for restriction of tire movement on front as well as rear.
5) Operator/ Fitter/ In-charge have to ensure that work is completed before starting / operating any
machine.
6) Operator blows horn or warning sound before starting of the machine.
PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: Rampura Agucha UG Mine
Location: North Vent Shaft

A person was injured

On 02nd April 2014 (in B Shift), at 08:45 PM, during mucking operation at shaft bottom, the mucking crew
pushed the empty kibble aside, and the mining mate was approaching towards the empty kibble to
release the chains from the kibble. At the same time, the cactus was in motion (as it was still filling some
muck into the nearby kibble), and the cactus swing-back and hit the mining mate at the back on his right
hip. Mining Mate sustained the blunt injury at his back side and shifted to hospital for treatment.

fnukad 2 vizSy 2014 dks (B ikjh esa ) jkf= 8: 45 cts “kk¶V ckWVe esa efdax vkWijs”ku ds nkSjku, efdax ny us
Åij ls vkbZ [kkyh cdsV dks “kk¶V ds ,d rjQ /kdsyk rFkk ekbfuax esV cdsV dh pSu dks eqDr djus ds fy,
[kkyh cdsV dh rjQ tk jgk Fkk A mlh le; dsDVl xfr”khy Fkk (og ikl gh j[kh cdsV esa dqN ed Mky
jgk Fkk) mlh nkSjku dsDVl okil ihNs vk;k vkSj ekbfuax esV dh dej ds nkfgus rjQ fupys fgLls ls
Vdjk;kA blls ekbfuax esV dks fiNys fgLlsa esa pksV vkbZ rFkk mls vkxs bykt ds fy, gkWfLiVy Hkstk x;kA

[ Example Photograph of the incident site ]

[ ?kVuk LFky dh mnkgj.k rLohjsa]
KEY LEARNINGS:
1. Prior to calling the empty kibble at the bottom, supervisor has to ensure the grab is in diagonally
opposite and is in stationary position.
2. Grab operator should stop the operation, if he sees/observe any person in the proximity of
cactus.
3. While lashing is in progress all persons at the bottom, should always keep their eyes towards the
cactus movement.
4. Strict compliance of SOP.
eq[; lh[k:
1- [kkyh cdsV dks “kk¶V ckWVe ij cqykus ls igys lqijokbtj dks lqfuf”pr djuk pkfg, fd xzsc Bhd
foijhr fn”kk rFkk fLFkj voLFkk esa vk x;k gS A
2- ;fn xzsc vkWijsVj dks dksbZ O;fDr dsDVl ds lehi fn[kkbZ nsrk gS rks mls izpkyu can dj nsuk pkfg, A
3- efdax ds nkSjku ckWVe esa mifLFkr lHkh O;fDr;ksa dk /;ku dsDVl ds ewoesaV dh rjQ gksuk pkfg, A
4- SOP dk iw.kZr;k vuqikyu djuk pkfg, A
 Hindustan Zinc Limited
Unit: RA-UG Mine

A person was injured……..

On 03.05.15, in ‘C’ shift at around 1.00 AM (04.05.15), while operator was lowering jumbo
canopy, a helper (Trainee jumbo operator) by mistake kept his finger at the telescopic
portion by which he sustained injury on tip of his right middle finger.

The IP was in the cabin of the drill while it was being moved to a new drill location. This is a
breach of standing instructions regarding seats, seatbelts, and specific instructions
concerning drill jumbos where only the operator may remain in cabin during relocation.

Position of IP’s finger

KEY LEARNINGS:

1. Compliance to existing SOP and standing instructions would have prevented this injury.
2. Additional back shift inspections by senior managers to confirm compliance to rules and procedures.
(The investigation is ongoing and additional learning’s will be shared upon completion. )

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: Fumer Project, CLZS

Fatal incident

On 28.03.2018, at 4:25 PM a fatal incident took place at BHP (Blower House site) of Fumer Project, CSC.
The detailed investigation under progress. As per preliminary investigation and findings, the Purlin fixing
job was in progress using man lift. The operator of man lift noticed some hydraulic oil leakage. The basket
was brought down. Operator called one of the helper (IP) to help for attending the leakage. The boom
was kept in lifted position and IP leaned into recess for boom cylinder. As per instructions of operator, IP
opened the valve causing the sudden release of oil pressure and instant lowering of boom. IP got trapped
between the boom and the body of the lifter. The boom lifted using crane, IP taken out and sent to
hospital where he was declared dead.

IP caught in between (body Housing with valve

of lifter and boom) on opened
other side

Key Immediate Actions for all HZL Operations

1. Inventory of Man-lift and fixed boom cranes must be prepared (Cherry Picker, Gene) with each piece
of equipment checked for any oil leak in lifting/telescopic cylinder. Identified problem must be
addressed by qualified mechanic or OEM himself under HZL supervision.
2. Competency review of every crane and man-lift operator must be undertaken. Where competency
does not meet standard the operator shall be stood down. Operators that are stood down should
undergo full competency assessment and retraining and certification.
3. No in-field maintenance of cranes or man-lifts shall be undertaken without the written permission of
the site president.
4. All checking maintenance work where similar possibilities are there (eg. Raised dump body of truck,
LPDT, raised Bucket of Loader, Machine kept on hydraulic or mechanical jacks etc), a positive
mechanical blocking must also be ensured
5. Project sites across HZL are to be inspected by line leaders over the next 3 days. Any unsafe
equipment is to be stood-down and any unsafe work stopped.

By implementing these immediate learnings we can keep our employees safe whilst we determine more
longer term actions to prevent a recurrence of this terrible incident.
 Hindustan Zinc Limited
Unit: Rampura Agucha Mine

A Fatality Happened.

On 14th December at around 10:36 P.M. IP (Dumper operator) at the end of “B” shift parked his
dumper 414 at southern side of parking yard and was crossing the parking yard while walking
towards the rest shelter. At the same time “C” shift dumper 412 was moving out from parking
area to go to Open Pit. IP came in front of the Dumper 412 and was hit and run over by the
Dumper 412.

S N

KEY LEARNING (Preliminary investigation) :

1. Avoid Man-Machine interface through exclusive pedestrian walk ways.

2. Avoid being in blind spots and line of fire of Heavy equipment movement.
3. SOP of “right of way” be followed. Traffic rule discipline must be maintained.
4. Equipment / truck operators to be more vigilant.
5. Audit the traffic related risks and review procedures, systems.
6. Every Change management to be reviewed for risk analysis
Detailed investigation is underway, learning will be shared.
 Hindustan Zinc Limited
Unit: Rampura Agucha

An HIPO incident happened (Dumper collision)…

On 13th Sep at 5:05 am a 110 t class dumper (No.22) collided with tail end of another 100 t dumper
(No.32) ahead of it owned and operated by DECO. The incident occurred at C shift end while both
the dumpers were returning to DECO rest shelter parking yard after dumping material at dump
yard. The operator cabin of dumper 22 got damaged and operator unhurt as he has put on seat
belt. The proximity sensor of dumper 22 checked and found in working condition. The haul road
width too was sufficient. Preliminary investigation revealed that operator of dumper 22 was in a
drowsy condition at the time of incident.

KEY LEARNINGS:

1. Safe distance of 30 meter must be maintained between HEMM. The traffic rules must be
adhered to and is to be enforced.
2. The operators be encouraged to report the fatigue and encouraged not to drive when feeling
drowsy.
3. The proximity sensors must be maintained in operational condition in all dump trucks. The
operators must adhere to the alerts of proximity alarm.
4. The eye lid tracking system to monitor driver fatigue to be installed.
5. Improving awareness by sharing of earlier incidents in tool box talk and to take adequate rest.
6. Regular audit & Review of shift end operation to avoid queuing.
 Hindustan Zinc Limited
Unit: Rampura Agucha

A HIPO Occurred……….
On 3rd April at 5:35 am in early morning hrs, dumper 301 collided with tail end of dumper 209 (both
100t class dump trucks). Dumper 301 after dumping at E4 dump was on the way to Ex-18 in pit to
take load, the dumper when reached near the rest shelter of HZL operators, lost the control and
collided with tail end of dumper 209 moving ahead of it. In the incident operator cabin of dumper
301 got damaged. The operator of dumper 301 was wearing the seat belt therefore no serious
injury happened. First aid was rendered due to abrasion below knee.

Detail investigation underway.

KEY LEARNING:

1. Safe distance of 30 meter to be maintained between HEMM and seat belt must be worn.
2. Strengthening of fatigue monitoring system is to be explored.
3. Proximity sensors must be in operational condition and rear Hazard light must always be on
and working from Dusk to Dawn.
4. Improving awareness by regular Toolbox talk, sharing of earlier incidents, consequences, safe driving
talk etc.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE .
 Hindustan Zinc Limited
Unit: SK Mine - Underground

HIPO – Incident occurred.

On 10.08.15, in ‘A’ shift at around 10:05 am, Passenger No-7 was standing near sub-station
at 300 mrl SKA2 and LHD-25 doing mucking from the south side and came from the south
FW drive inside and hit the front right of passenger. At the time of incident no person was
inside the passenger. One person standing next to the Passenger carrier fell down. No injury
occurred.

Area of accident

KEY LEARNINGS:

1. Awareness in Hazard Identification at work Place to be strengthened.

2. Traffic SOP need to be revisited to identify and bridging the gaps
3. System of signalling while LHD in operation to be implemented
4. No vehicle should be parked in the active working area of HEMM.
PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: SK Mine - surface

HIPO occurred...
On 29\06\2016, in ‘A’ shift at 03:45 pm. One Drinking water supply tempo (RJ30 GA-2680) after filling
water in the water cooler at Normet workshop while coming out in the reverse direction touches one
of the Normet Employee who was engaged in the general checking of Utility machine in shift starting.
The person tried to escape and fell down. He was sent to hospital but no injury.

Position of
affected person

KEY LEARNINGS:

• Man Machine interaction to be eliminated

• Rear View mirror to be used and helper should assist while reversing
• Reverse movement of vehicle to be eliminated.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
RA- UG Mine

HIPO Incident occurred at RA UG Mine

On 19.04.2018, at around 05:00 PM, CAT Truck CT-08 was going down through North decline while
truck CT-9 was coming up. On seeing CT-8 coming down near ND DSP-6 the operator of CT-9 stopped
the truck. Operator of CT-8 also applied brakes but before it could halt, it collided head on with
stationery truck CT-9. There were no injuries but CT-9 radiator, front cover damaged
After analysis of Electronic Control Module (ECM) data of CT-8, it was found that CT-08 operator
applied the brakes only 3 seconds before the collision although there was around 35m visibility. The
speed of truck was approx. 20 KMPH

Detailed investigation is under progress.

KEY LEARNING:

1. As a standard practice as soon as any vehicle/equipment is seen in front, both the vehicles must
stop safely and immediately.
2. Functioning flashing beacons are required on all vehicles
3. Wherever possible, one way traffic to be implemented and noted in the traffic management
plan.
4. Anti collision warning systems / vehicle tracking systems are to be explored for UG equipment
5. Speed limits to be followed – breaches shall result in disciplinary action. Speed warning system
to alert operators
6. Regular awareness to operators through Tool Box Talk, trainings etc

PLEASE ENSURE THAT IT CANNOT HAPPEN AT YOUR SITE

 Hindustan Zinc Limited
UNIT: SK MINES

HIPO incident – SK Mines

On 19.04.2018, at 08:45pm, LPDT was at loading point 65mRL south drive. Shift I/C - HZL driving RBO
(with Beacon light & hazard light on), along with TCL production shift in-charge gave pass to Jumbo
travelling towards north drive by positioning RBO in front of LPDT loading point. While RBO was waiting
for jumbo to cross, at the same time LPDT operator moved forward to position LPDT without noticing RBO
ahead and hit the RBO(damaging the rear gate). Both the persons in RBO were wearing seat belts. No
injury. Preliminary investigation shows that there was a communication gap between the LPDT operator
& RBO operator.

Detail Investigation is under progress

This side of
RBO was
hit by LPDT

Key Learnings:

1. No LMV shall go near the loading point and parked at a loading point. The LMV/Machines to be
parked in a safe location away from any mobile equipment. In case it is required to go near machine,
the operator must be informed first through positive communication
2. Reflective tape to be fixed at all sides of LMV. Flashing beacon on a mast (Hazard Light) to be
provided
3. Driving skills to be validated periodically for all LMV & HEMM operator.
4. Refresher training on defensive driving for all LMV operators to be imparted periodically.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE
 Hindustan Zinc LimitedUnit:
Rampura Agucha

A HIPO happened. Dumper collided……..

On 6th May at 5:50 AM dumper 504 collided with tail end of dumper 31 both 100t class dump trucks.
Dumper 31 was on the way to tailing dam to dump waste, when it reached 390mRL in the foot wall there
were two dumpers stopped in a queue to give way to 221t dumper, so the dumper 31 also stopped
behind them. After passing of 221t dumper two 100t dumpers left to dump site and dumper 31 was
about to leave at that time dumper 504 hit from the behind the tail end of the dumper 31. The operator
cabin of dumper 504 got damaged, the operator had worn seat belt and this prevented injury. The
proximity sensor of dumper 504 was in working condition, illumination was sufficient and haul road width
adequate.

Preliminary investigation revealed that operator of dumper 504 was in a drowsy condition at the time of
incident.

Detailed investigation is in progress, meanwhile please ensure

KEY LEARNING:

1. Safe distance of 30 meter to be maintained between HEMM. Traffic rules to be followed.

2. Fatigue monitoring system to be explored and implemented
3. Encourage worker to report fatigue
4. The proximity sensor indication to be religiously adhered to.
 Hindustan Zinc Limited
Unit: RA-UG Mine

A HIPO happened …….…

On 12th May in A shift at around 9.50 AM in North decline, -155 mRL junction, the IP along
with Jumbo operator was manually un-reeling the trailing cable of Boomer (B-2) to hook up into
the Gate End Box, with the Jumbo parked in the decline. Suddenly Jumbo rolled back and
stopped hitting the side wall. IP got caught in the space between jumbo and the decline wall,
causing blunt injury on left of his hip. He was sent to Zinc Hospital for further treatment.

Position of IP

Investigation underway

KEY LEARNING:

1. Equipment parked on gradient shall be secured with jack down (if available) or by applying
wheel choke.
2. Operator shall not leave the machine. If at all required, the machine shall be secured by jacks
or wheel chock.
3. Effectiveness of brakes shall be checked regularly.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: RA-UG Mine

A HIPO happened…

दनांक 12.05.2016 क थम पार म करब 9.50 बजे, नाथ डलाइन -155 एम आर एल के संयोग !थल
पर, चो
टल $यित जंबो ऑपरे टर के साथ बूमर - २ (बी-2) क +े ,लंग केबल को गेट ए-ड बॉस के साथ बांधने के ,लए
0म को खोल रहा था तथा जंबो डलाइन म खड़ी हुई थी I अचानक जंबो पीछे क तरफ लुढ़कने लग गयी तथा साइड
दवार म टकराके ;क गई I इस दौरान चो
टल $यित जंबो तथा साइड दवार के बीच क जगह म फंस गया I इस दौरान
उसे अपनी कमर के बाएं
ह!से म गहर चोट आ गयी

Position of IP
Investigation underway
INITIAL KEY LEARNINGS:

1. मशीन को ढलान म पाक करने से पहले जैक अथवा $हल चोक के जAरये ि!थर करे I

2. ऑपरे टर मशीन से Bनचे नहं उतरे गा जब तक क मशीन को जैक अथवा $हल चोक के Cवारा ि!थर कर
दया गया
हो I

3. Dेस क कायकरता क जाँच करके ह मशीन को काय!थल पर ले जाया जाये I

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: S.K. Mine

An LTI incident happened …..…

On 04.05.2017 in “B” shift at about 7:00 PM, the drill jumbo operator (IP) was adjusting the feed
extension control valve for rock bolt drilling. IP was standing behind the feed with the power pack
of the machine kept ON and the feed extension lever from the control panel was also in operative
position. When the control valve was operated by the IP, the hydraulic circuit got charged and feed
cylinder got activated. This resulted in the backward movement of the feed and hitting the left
thigh of IP causing injury.

Position of the control

switch outside
machine.

Key Learning:

1. Exploring the possibility of changing the position of the control valve to eliminate the risk
2. The power pack must be switched off while operating the feed extension valve.
3. The boom of the jumbo must be positioned in such a way that operator wouldn’t be in line of
fire. (towards Right side)
4. The operating levers must be in neutral position.
5. The hydraulic pumps shall be switched off (switching off the power pack & shutting off the
engine) while carrying out any manual activity inside the working area of the booms including
control valve adjustment.
6. Always switch off the power pack whenever coming out of cabin.
7. SOP is to be reviewed and revised. The operators should be imparted the refresher training on
SOP

PLEASE ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.

 Hindustan Zinc Limited
Unit: Roaster2, Hydro2, CLZS

A serious injury happened

On 07th Sept 2016 at around 04:15 PM during checking double earthing of motor of running
Slinger machine, I.P. found some spilled concentrate over the motor terminal box and tried to
clean the Terminal Box cover by hand. Accidently, IP’s right hand fingers came in contact with
nearby drive pulley. IP immediately he removed his hand but sustained lacerated wounds of soft
tissues over right hand fingers tips. IP was wearing the hand gloves.

After rendering first aid in plant dispensary, IP was sent to Aksar hospital, from where he was
referred to Udaipur for further treatment.

Investigation in Progress

Location where I.P.

sustained injury

KEY LEARNINGS:

1. Work Permit should be taken before checking any running machine/ equipment.
2. 360 degree Machine guarding should be ensured such that no person could reach the
rotating parts/ nip points.
3. Cleaning if needed on running equipment, proper tools to be used to avoid any body part
coming in line of fire.
4. The deposition of dirt / material should not be allowed
5. Risk Assessment / JSA should be done before start of job.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit:DSC Pb

A LTI incident happened at Dariba smelter …….…

On 28.06.2018 at around 23:30 hrs. SKS furnace shutdown was going on. During built up cleaning of
lead bullion ladle of SKS furnace with Brokk machine by operator of Core Infinity services Pvt Ltd, chisel
got stuck in lead and operator tried to remove it. During this cleaning operation chisel suddenly came
out and Brokk machine got displaced from its position with jerk. The right jack of machine hit IP left
leg on little finger area. IP was wearing all PPEs. IP was taken to hospital, X-ray was taken and found
fracture on left leg little finger. IP referred to Mewar Hospital, Udaipur for further diagnosis

Position of IP’s
foot

Key Learning:

1. During operation, Brokk machine position to be monitored by operator. Line of fire to be clearly
defined with proper barricading
2. Thorough risk assessment to be done for one time mechanized jobs
3. Care to be taken for lead metal removal with machine, as chances of chisel to stuck are high.

PLEASE ENSURE THAT NO SUCH INCIDENT TAKES PLACE AT YOUR SITE.

 Hindustan Zinc Limited
Unit: Zinc Smelter Debari

An MTI incident happened at Roaster-2 ….

On 26.06.2017, at 08:45 PM in roaster-2, cyclone choking was being cleaned through hand-hole of
rotary airlock valve. After poking when the lumpy material drained out from the cyclone the IP
(fitter- contract employee) went near the hand-hole to see the cleanness of RAV. During checking
his right hand with leather gloves caught in-between RAV flights & casing. He pulled back his hand
but sustained injury on the tip of the middle and ring fingers and the glove got stuck in the rotary
valve. IP was given first aid and referred to Mewar hospital for further treatment as IP was diabetic.
IP resumed duty next day after treatment.

Preliminary investigation revealed the following causes.

1. Cyclone choking removal through RAV is an on line cleaning activity for which electrical isolation
is exempted. Activity also exempted from PTW being a routine activity for which SOP is made &
cleaning crew is trained.
2. Checking of the cleanness of chocking was not the part of IP’s job and he did it without
intimating anyone.

Hand hole Leather hand

gloves stuck in
rotary valve

KEY LEARNINGS: -

1. Opening / closing & cleaning activity must be done by single team

2. All Local Control Switches (LCS) should have locking arrangement
3. Rotary air lock valve must be in eye sight of operator standing at Local Control Switch
4. Complete exception list to be reviewed with respect to the requirement of standards.
5. One must not put his/her body part/s in line of fire
6. Job must be performed after ensuring proper LOTOTO ( zero energy state must be ensured)
7. False air entry points must be sealed in roaster gas stream in order to eliminate lumps
formation.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Rampura Agucha UG Mine

An MTI happened …….…

On 03.09.2017 at about 06:40 AM, Personnel carrier (PC-8), after boarding of persons, was ready
to go UG. Another PC was behind it so the operator started reversing towards the main road
side. One of the LPDT (MT-12) was coming from HEMM workshop at that time. Both operators
had some communication gap and vehicles moved towards each other in anticipation that other
one would stop. The truck stopped but reversing PC touched LPDT before it could stop. Because
of the jerk IP’s left elbow hit the sidewall of the PC causing swelling. IP was sent to the Hospital
for medical advice. No injury detected.

(Site Layout)

KEY LEARNINGS:

1. At PC parking yard area, the right of way is of PC. Awareness trainings on right of way to be
imparted.
2. The layout of the PC yard to be reviewed and modified to eliminate the reversing.
3. Whenever there is a communication gap, confusion, both vehicles must stop.

PLEASE ENSURE IT CANNOT HAPPEN AT YOUR SITE.

High Potential Incident- First Aid occurred
On 11th December2015 at 18:15 hrs, concentrate trailer (Reg. no. RJ 06 GA 7424) was coming from
Weigh Bridge to DSC-Zinc RMH and calcine bulker (Reg. no. RJ 09 GB 0150) was going towards
weighbridge side after loading. The concentrate trailer driver took a turn towards the parking of RMH (T-
Junction) Both the drivers couldn’t judge the movement of other vehicle and in a state of confusion, the
vehicles slightly hit each other. Both were at low speed.

Due to collision, the calcine bulker driver got a impact on his right leg knee. He was given First Aid at Zinc
Hospital.

KEY LEARNING:

1. Risk assessment for traffic to be conducted inside the premises.

2. Exploring implementation of traffic lights at junctions and other places
3. Enforcing use of turn indicators / signals by vehicle drivers
4. Strict compliance to traffic rules.

PLEASE CHECK AND ENSURE THAT THIS CANNOT HAPPEN AT YOUR SITE.
 Hindustan Zinc Limited
Unit: Kayad Mine
Location: 275 mRL North section

MTI Alert

On 14th January 15, in B shift, around 9:15 PM Atlas Copco LPDT (30 tonner) was under breakdown
at 272 mRL in North decline and the technicians were called for repairing the same. The technicians
came in the Normet make RBO for attending the breakdown. The RBO was parked at approach X-
cut of 275mRL. The mining mate of “B” shift wanted to shift the RBO to pass other equipment. One
person went to call Atlas Copco technician for this purpose who was working on breakdown LPDT.
Meanwhile, the Mining Mate himself went inside the RBO, started & operated. He tried to move the
equipment towards the decline but could not control the RBO and hit the rear dump box of LPDT
which was standing there approx. 25 mtrs away. He got minor injury on forehead. He was given first
aid in underground and brought to surface then sent to Hospital.

KEY LEARNINGS:
• He was not trained and only authorized person to operate the RBO.
• The ignition key of RBO was left inside vehicle, while it was parked. The key is always to be
taken out by the operator/Driver whenever he is leaving the seat.