Telemonitoring System in Mines – DGMS Guidelines, Use, Maintenance & 25 MCQs

🧾 DETAILED NOTES

1️⃣ Introduction

Modern mines increasingly use Telemonitoring Systems to monitor real-time parameters of mobile machinery and the environment. For machinery (HEMM), this includes equipment health, engine performance, brake temperatures, tire pressures, and machine location. DGMS promotes the use of telemonitoring to prevent accidents, improve machine reliability, and ensure proactive maintenance.

(Note: This article focuses on machinery telemonitoring. For environmental (gas) telemonitoring, see Reg. 169).

2️⃣ Purpose of Telemonitoring System (Machinery)

Prevent sudden mechanical failures (e.g., brakes, engine).
Reduce HEMM-related accidents (collisions, over-speeding).
Monitor operator behaviour (fatigue, harsh braking).
Reduce maintenance downtime through predictive data.
Provide accurate digital logs for audits.
Support preventive and predictive maintenance schedules.

3️⃣ DGMS Legal & Technical Framework

Reference	Description
The Mines Act, 1952 – Sec. 18 & 23	Safety & supervision duties for machinery.
CMR 2017 – Reg. 106, 107, 108	Machinery operation, dump safety, and transport rules.
DGMS Circular (Mech.) 2019	Recommendations for telemonitoring for HEMM safety.
ISO 15143	Earth-moving machinery telematics standard.

4️⃣ Major Components of Telemonitoring System

GPS Module (Location tracking)
IoT Sensors (Brake Temp, Engine Oil Pressure, etc.)
Data Acquisition Unit & Communication Gateway (GSM/WiFi)
Engine Health Module
Fuel Management Module
Vibration & Shock Sensors
Real-time Dashboard (Surface Control Room)

5️⃣ Functions in Mining

🔧 Equipment Monitoring: Engine rpm, Brake oil temp, Hydraulic pressure, Coolant temperature, Transmission status.

🛑 Safety Monitoring: Over-speed alerts, Hard braking, Harsh cornering, Machine immobilization in unsafe conditions.

📊 Productivity Monitoring: Load count, Cycle time, Idle vs working hours, Haul road delays.

6️⃣ Maintenance Requirements

DGMS mandates that telemonitoring systems must be functional at all times on machinery where they are installed.

Daily: System health check by operator/supervisor.
Periodic: Calibration of critical sensors (e.g., brake temperature) as per OEM.
As needed: Software updates, battery/connector inspection, repair/replacement of faulty sensors.

Record keeping: Daily telemonitoring logs, fault reports, and monthly performance summaries must be reviewed by the Engineer and Manager.

7️⃣ Responsibilities

Role	Responsibility
Manager	Ensure system is installed and operational; Review daily reports; Stop machines with faulty systems.
Engineer	Ensure calibration & maintenance; Replace defective sensors; Maintain logs.
Operator	Report faults immediately; Follow telemonitoring warnings (over-speed etc.).

⚙️ QUICK ONE-LINERS (Revision Points)

Telemonitoring = real-time machine health monitoring.
Helps detect engine, brake & hydraulic faults.
Mandatory/recommended for large HEMMs in opencast mines.
Requires daily health check and periodic calibration.
DGMS Circulars promote it for predictive maintenance.
Supports over-speed control and operator discipline.
Faulty system → machine must not be used (if mandated).
Logs reviewed by Manager daily.
Improves productivity & safety.
Reduces breakdowns and transport accidents.

🧠 DESCRIPTIVE MODEL Q&A

Q. Explain the use and maintenance of telemonitoring systems in mines as per DGMS guidelines.

Answer:
Telemonitoring systems (Telematics) are used on HEMM to monitor real-time operational and safety parameters like engine temperature, brake condition, hydraulic pressure, and vehicle speed. DGMS encourages their use (Ref: Circular 2019) to prevent equipment failures and transport accidents. The system must be inspected daily (pre-start check), and sensors must be calibrated regularly as per OEM guidelines. Data logs are reviewed by the Manager/Engineer to schedule predictive maintenance and monitor operator behavior. Machines must not be operated if critical telemonitoring safety alerts are active or the system is faulty.

🧮 25 DGMS-Based MCQs (5 Options Each)

Q1. Primary purpose of telemonitoring system on HEMM:

Solution: Telemonitoring (or telematics) tracks the real-time status of machinery for safety and maintenance.

Q2. Telemonitoring is mainly used on:

Solution: These systems are most beneficial on high-value, mobile Heavy Earth Moving Machinery (HEMM).

Q3. Engine health data includes:

Solution: Coolant temperature, engine oil pressure, and RPM are key engine health parameters.

Q4. Telemonitoring helps detect:

Solution: GPS and speed sensors in the telemonitoring system provide over-speed alerts to the operator and control room.

Q5. Telemonitoring communication may use:

Solution: GPS (for location) and GSM (mobile network for data transmission) are the most common communication technologies used.

Q6. DGMS recommends telemonitoring for:

Solution: The campaign and circulars are focused on improving the safety of heavy machinery (HEMM).

Q7. Telemonitoring prevents:

Solution: By providing real-time warnings (e.g., brake failure, over-speed), the system helps prevent accidents.

Q8. Daily telemonitoring check done by:

Solution: The operator must perform a pre-start check, and the engineer must ensure its overall functionality.

Q9. Faulty telemonitoring means:

Solution: If a safety-critical monitoring system (like brakes or steering alerts) is faulty, the machine is unsafe and must be stopped.

Q10. Telemonitoring sensors require:

Solution: Sensors must be periodically calibrated against a known standard to ensure their readings are accurate.

Q11. Telemonitoring helps in:

Solution: By tracking trends (e.g., rising engine temperature), it allows maintenance to be scheduled *before* a breakdown occurs (predictive).

Q12. Telemonitoring unit includes:

Solution: IoT (Internet of Things) sensors are the core components that collect data (temp, pressure, etc.).

Q13. Brake temperature monitored for:

Solution: Monitoring brake temperature is a critical safety function to prevent brake failure due to overheating.

Q14. Telemonitoring logs reviewed by:

Solution: The Mine Manager (or their designated engineer) is responsible for reviewing performance and safety logs.

Q15. Standard for telematics:

Solution: ISO 15143 is an international standard defining telematics data for earth-moving machinery.

Q16. Telemonitoring helps reduce:

Solution: By enabling predictive maintenance, it reduces the number of unexpected and costly machine breakdowns.

Q17. System housing must be:

Solution: To survive the harsh, dusty mining environment, all electronic components must be in rugged, dust-proof (IP-rated) enclosures.

Q18. GPS module used for:

Solution: The Global Positioning System (GPS) module provides the real-time location of the machinery.

Q19. Fault reports stored in:

Solution: All faults, inspections, and repairs must be recorded in the machine's statutory logbook.

Q20. Telemonitoring helps detect:

Solution: Telemonitoring tracks when the machine is working, idling, or being misused (e.g., over-speeding), which helps improve operational efficiency.

Q21. Maintenance includes:

Solution: As a digital system, maintenance includes keeping the firmware and monitoring software up-to-date.

Q22. Over-speed alert helps prevent:

Solution: Alerting the operator to an over-speed condition is a direct safety intervention to prevent loss of control and accidents.

Q23. Telemonitoring stores data in:

Solution: The data is transmitted from the machine and stored digitally on a central server or cloud platform for analysis.

Q24. Faulty sensor must be:

Solution: A faulty sensor provides false data, making the system useless. It must be repaired or replaced.

Q25. Telemonitoring improves:

Solution: The system enhances safety (by preventing accidents) and efficiency (by optimizing maintenance and performance).

🔗 INTERNAL LINKS

Related Topic	Read More On...
HEMM Safety	Safety Features in Crawler/Tyre Mounted Machinery
Opencast Transport	Accidents Due to Dumpers and Tippers
Machinery Maintenance	Appointment of Engineers for Machinery Safety
Risk Assessment	DGMS Campaign on "Risk Calculator"

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