MCL achieves 70% improvement in overall illumination uniformity index leading to greater operational efficiency
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Identify Areas Of Risk With Scaling Workforce
Mahanadi Coalfields Limited (MCL), one of India’s leading coal-producing companies and a subsidiary of Coal India Limited, had been strategizing to enhance workplace safety, operational efficiency, and compliance with Environmental, Social, and Governance (ESG) benchmarks. At its Gopalpur Open Cast Project (GOCP), located in the Jharsuguda district of Odisha, MCL faced critical challenges associated with recording and maintaining adequate illumination across key operational zones.
An internal illumination survey revealed that the existing lighting infrastructure especially in high-traffic operational areas such as haul roads, service roads, workshop zones, and dispatch points could be under illuminated. The consequences of this sub-optimal lighting were significant, leading to poor visibility in night operations posed high risks to personnel and vehicular movement, increasing the likelihood of accidents involving heavy machinery and haul trucks. Inefficient lighting made it difficult for operators to navigate the terrain with precision, particularly during early morning and night shifts. This led to a reduction in productivity and delays in material dispatch and transport cycles.
Moreover, MCL’s compliance with DGMS defined statutory safety norms and illumination standards was at risk due to the lack of adherence with the appropriate illumination protocols.
The legacy system relied on conventional lighting that not only consumed more power but also lacked energy efficiency, inflating operational costs and the site’s carbon footprint.
"At Garjanbahal, we used Bidaal's AI-based illumination planning & designing to develop a lighting plan for our open-cast coal mines, based on the survey’s gap analysis. The most important feature we liked was that the simulation model gave us a fully optimized solution adhering to the DGMS guidelines."
Jugal Kumar BorahDirector(Technical), MCL
Identify Areas Of Risk With Scaling Workforce
Recognizing the urgent need for a sustainable and intelligent lighting solution, MCL collaborated with Bidaal to have a complete digital system in place. Bidaal offered not only a digitalized solution for illumination recordings, but also an energy-efficient illumination plan tailored to the specific operational requirements and geographical layout of the GOCP.
To conduct a comprehensive lux survey at GOCP, a compact device equipped for recording and storing lux values was securely mounted on a Light Motor Vehicle (LMV) to capture real-time illumination data across operational zones. Simultaneously, two drones were deployed to map the entire site and evaluate the existing lighting layout. This dual-approach enabled a thorough assessment of the illumination plan currently in use, providing critical insights into both ground-level lighting conditions and illumination infrastructure alignment.
Secondly, the recorded illumination data was processed using specialized software to generate a comprehensive analytical report. This report provided detailed insights into the lux levels across various zones and facilitated a comparison against the compliance benchmarks set by DGMS. Additionally, a heatmap and discreet image were generated to offer a clear, timestamped representation of the recorded data, enabling precise identification of under-illuminated areas and overall lighting performance.
The aerial mapping of the existing illumination infrastructure, combined with lux data collected through the WISE device survey, was instrumental in identifying key shortcomings in MCL’s current lighting plan. Leveraging these data points, the AI-driven solution provided targeted recommendations to optimize the existing infrastructure, ensuring enhanced illumination effectiveness and improved operational safety across the site.
80% Reduction In Incidents
The improved lighting infrastructure led to a measurable reduction in safety incidents during night operations. Enhanced visibility for operators and ground personnel significantly mitigated the risk of accidents involving heavy-duty vehicles.
Travel and turnaround times for dumpers and excavators improved due to better navigability and visibility. This led to improved cycle times and greater productivity across the mining value chain.
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