Safety Features in Crawler and Tyre Mounted Machineries Used in Mines – DGMS Guidelines

🏗️ Detailed Notes

1️⃣ Introduction

Mining operations rely heavily on heavy earth-moving machinery (HEMM) such as shovels, dumpers, dozers, drills, excavators, and loaders, either crawler-mounted or tyre-mounted. Accidents involving these machines often result in fatalities due to rollovers, collisions, or mechanical failures. To prevent such accidents, DGMS mandates that specific safety features must be incorporated, maintained, and periodically tested in all mobile mining machineries. These requirements are derived from Regulation 126 of CMR 2017, DGMS Circulars (Tech.) No. 08/2009, 02/2015, and 06/2017, and MMR 1961 – Reg. 126 (for metal mines).

2️⃣ Applicable Machinery

Hydraulic Shovels
Crawler & Wheel Dozers
Excavators
Dumpers / Haul Trucks
Drill Machines
Wheel Loaders
Crane-mounted vehicles

3️⃣ Mandatory Safety Features (as per DGMS Guidelines)

System	Safety Features Required
Braking System	Service, Parking & Emergency brakes. Air/hydraulic-assisted type.
Steering System	Power steering with fail-safe mechanism.
Rollover Protection (ROPS)	Cabin structure designed to protect operator in case of machine overturning.
Falling Object Protective Structure (FOPS)	Prevents injury from rock or debris falling on cabin.
Rear-View Camera / Proximity Alarm	Audio-visual alert for reversing and blind spots.
Seat Belt with Interlock	Operator seat belts mandatory with safety interlock to prevent machine movement without fastening.
Fire Suppression System	Automatic fire extinguishing in engine & hydraulic compartments (for dumpers/shovels > 100T).
Lighting & Signalling	Headlights, tail lamps, beacons, reverse horn, and reflective strips.
Emergency Stop Switch	Located near operator’s seat and on ground access points.
Tyres/Tracks Condition	Regular inspection and replacement of worn-out tyres or track pads.
Speed Governor	Installed and calibrated as per mine condition.
Horn and Reverse Alarm	Audible at 30 metres minimum distance.
Access & Egress	Safe handrails, anti-skid steps, and ladders.
Cabin Ergonomics	Dustproof, vibration-isolated operator cabin with adequate visibility.
Automatic Engine Shut-off	Provided in case of overheating or low oil pressure.

4️⃣ Maintenance and Inspection

All machines must be examined weekly by a competent mechanical engineer and findings entered in Machinery Inspection Book (Form M-1).
Daily pre-start checks by operators using safety checklist.
Brake tests every 7 days.
Fire suppression system inspected monthly.
DGMS-approved contractors must perform periodic calibration of alarms and speed governors.

5️⃣ Training & Competency

Operators must hold a valid Driver/HEMM Competency Certificate under Rule 29C, Mines Rules 1955.
Periodic refresher training on equipment safety and emergency procedures.
Mock drill for fire suppression and brake failure situations.

6️⃣ Common Accidents Prevented by Safety Features

Type of Accident	Preventive Feature
Machine Rollover	ROPS, seat belt interlock
Collision	Reverse camera, alarms
Brake Failure	Dual braking system
Fire in engine bay	Auto fire suppression
Operator fall	Access ladder, handrails
Electrical fire	Circuit breaker & cut-off switch

⚡ Quick One-Liners (Revision Points)

DGMS Circular 08/2009 covers HEMM safety.
ROPS & FOPS mandatory for operator protection.
Seat belts and alarms must be functional.
Fire suppression system compulsory for large HEMM.
Reverse alarm & camera – essential safety aids.
Daily pre-start checks to be logged.
Emergency stop switch near operator seat.
Braking test – weekly.
All HEMM to have speed governor.
Form M-1 used for inspection records.

🧠 Descriptive Model Question & Answer

Q. Discuss the safety features to be incorporated and maintained in crawler and tyre-mounted machineries used in mines as per DGMS guidelines.

Answer:
The DGMS mandates that all crawler- and tyre-mounted machinery used in mines (such as dumpers, shovels, dozers, and drills) must be equipped with specified safety features to ensure safe operation. Under Reg. 126 of CMR 2017 and DGMS Circulars 08/2009 & 02/2015, the essential features include: ROPS and FOPS for operator protection, dual braking system (service and parking), seat belt with interlock, rear-view camera and proximity alarm, automatic fire suppression system in large equipment, adequate lighting, reflective tapes, and reverse alarm.

Machines must undergo weekly inspection, with test results recorded in the Machinery Logbook (Form M-1). Operators must perform daily safety checks before starting the equipment. Proper training, preventive maintenance, and adherence to DGMS standards significantly reduce accidents involving heavy machinery in both coal and metal mines.

🎯 25 MCQs – Safety Features in Crawler/Tyre Mounted Machineries

Q1. Regulation for machinery safety in coal mines:

A. Reg. 126, CMR 2017 B. Reg. 99A, CMR 2017 C. Reg. 145, MMR 1961 D. None

Q2. ROPS stands for:

A. Roll Over Protective Structure B. Roof Over Protective System C. Rescue Operation Plan System D. None

Q3. FOPS is used to protect against:

A. Falling objects B. Fire C. Flood D. None

Q4. Fire suppression system is mandatory in:

A. Large dumpers & shovels (>100T) B. All light vehicles C. Only drills D. None

Q5. DGMS Circular on HEMM safety:

A. 08/2009 B. 01/2010 C. 07/2018 D. None

Q6. Seat belt interlock prevents:

A. Machine movement without seat belt B. Overloading C. Tyre burst D. None

Q7. Reverse camera aids:

A. Collision prevention B. Fire detection C. Dust monitoring D. None

Q8. Fire suppression inspected:

A. Monthly B. Weekly C. Annually D. None

Q9. Operator competency under:

A. Rule 29C, Mines Rules 1955 B. Reg. 146, CMR 2017 C. Rule 35, MMR 1961 D. None

Q10. Brake testing frequency:

A. Weekly B. Daily C. Monthly D. None

Q11. Illumination in HEMM includes:

A. Headlight, beacon, tail lamp B. Decorative lights C. None

Q12. HEMM safety logbook form:

A. Form M-1 B. Form R-3 C. Form B D. None

Q13. Overheating auto shutoff system prevents:

A. Engine fire B. Vibration C. Braking D. None

Q14. Speed governor ensures:

A. Safe speed limits B. Higher speed C. Braking D. None

Q15. Tyre inspection done:

A. Daily B. Monthly C. Yearly D. None

Q16. Operator cabin must be:

A. Dustproof & vibration-free B. Open C. Unsafe D. None

Q17. Reverse horn must be audible up to:

A. 30 metres B. 10 metres C. 5 metres D. None

Q18. DGMS Circular 02/2015 refers to:

A. Safety in Earth-moving Machinery B. Mine Ventilation C. Dust Control D. None

Q19. FOPS used in:

A. Excavators B. Pumps C. Compressors D. None

Q20. Anti-skid ladder improves:

A. Safe access B. Speed C. Comfort D. None

Q21. Automatic shut-off activates due to:

A. Low oil pressure / overheating B. Operator command C. Noise D. None

Q22. Reflective strips improve:

A. Visibility B. Cooling C. Speed D. None

Q23. Cabin visibility improved by:

A. Cameras & mirrors B. Painting C. Lighting D. None

Q24. DGMS inspects HEMM safety during:

A. Periodic inspections B. Annual audits C. None

Q25. Integrated safety system ensures:

A. Operator & equipment protection B. Faster operation C. None

🔗 Internal Linking Suggestions

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Safety Training	DGMS Tech Circular 6/2024 - Safety Training Updates

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