Useless Machine Kits and Free Plans

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Those of you who have been in my class have seen this little toy. I have it labeled “LOCK-OUT/TAG-OUT NOT REQUIRED even though it’s an electrical device, because it’s smarter than most. It doesn’t do much, but as I say, I’m easily amused. In fact, all it does if you flip the toggle switch on the top is turn itself back off… hence the safety without LOTO. Turn it on and a little plastic piece comes out, turns itself back off and then quickly retreats into the box for the next round.

You can buy kits or find your way to free plans here. There are also some entertaining videos to watch of useless boxes in action.

Use this file to print your own label.

Fatality #16 for Coal Mining 2012

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On Wednesday, September 26, 2012, a 32-year old section foreman with 12 years of experience was killed by a roof fall at Kopper Glo Mining’s Double Mountain Mine. He was operating the continuous mining machine to excavate a roof cavity in preparation for the installation of a belt conveyor drive. The foreman was positioned approximately 8 feet inby the last row of permanent roof support when a section of the unsupported roof, approximately 6½ feet long, by 6 feet wide, by up to 8 inches thick fell, striking the victim and pinning him to the mine floor.

Best Practices
  • Always post the end of permanent roof support with a readily visible warning or physical barrier to impede travel beyond permanent roof support. This serves to alert all miners as they approach a danger zone.
  • Never travel beyond permanent roof support.
  • Never expose any portion of your body inby the last row of undisturbed permanent roof supports.
  • Make frequent, thorough roof examinations and be aware of changing roof conditions at all times.
  • Give extra attention to the roof after activities that cause roof disturbance.
  • Take extra precautions when cutting out roof support or mining above the normal roof line, such as mining a shorter depth of cut, then install two rows of roof bolts before continuing to mine.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

Fatality #15 for Coal Mining 2012

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On Thursday, September 13, 2012, a 61-year-old general inside laborer with 38 years of mining experience was killed when he was struck by a section of mine roof. The victim was removing a roof bolt from an older area of the mine which was no longer in contact with the mine roof. A section of mine roof fell, striking the victim.

Best Practices
  • Before performing work in any area of the mine, observe the roof and ribs for hazardous conditions and correct hazards immediately.
  • Install additional roof supports prior to removing old supports.
  • Perform sound and vibration testing before installing or removing permanent roof supports.
  • Only remove roof supports under the direction of a manager or foreman.
  • Use roof screen (wire mesh) to control loose roof in long-term travel roads.
  • Take extra precautions when working or traveling in older areas of the mine, paying particular attention to deteriorating roof conditions.
  • Make frequent roof examinations and be alert to changing roof conditions at all times. Give extra attention to the roof after activities occur that could cause roof disturbance.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

Hazard Alert: Working in Confined Spaces

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Working in confined spaces can be very dangerous. A confined space is an area with poor or no airflow. Examples of
confined spaces include:

  • Tanks
  • Bins
  • Covered Pits
  • Silos

Poor airflow allows accumulation of dangerous gases in confined spaces. Before a miner enters a confined space, the
atmosphere needs to be checked for adequate oxygen concentration and the accumulation of flammable or harmful gases.

MSHA has issued a hazard alert. Download the alert here (pdf).

Fatality #14 for Metal/Nonmetal Mining 2012

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On September 26, 2012, a 79-year old foreman with 56 years of experience was killed when he was run over by the dozer he had been operating. The victim exited the cab and was positioned on the left track checking the engine throttle linkage when the dozer moved forward.

Best Practices
 

  • Inspect equipment before placing it in operation for the shift.
  • Correct safety and operational defects on equipment in a timely manner to prevent the creation of a hazard to persons.
  • Establish safe work procedures and identify and remove hazards before beginning a task.
  • Prior to beginning work, ensure that persons are task-trained and understand the hazards associated with the work being performed. Know and follow safe work procedures before beginning repairs.
  • Block dozer against motion by lowering the blade and ripper to the ground and setting the parking brake. Set the transmission lock lever to ensure the transmission is in neutral.
  • Do not place yourself in a position that will expose you to hazards while performing a task.
  • Monitor personnel routinely to determine that safe work procedures are followed.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf), Overview (powerpoint), Overview (pdf).

Fatality #13 for Metal/Nonmetal Mining 2012

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On September 22, 2012, a 34-year old contract laborer with 6 days of experience was killed when he fell through a 6 ft. X 8 ft. hole that was partially covered with 2″ X 4″ boards and ¾ ” thick plywood. He fell into a chute landing on a belt conveyor 30 feet below. The victim was assigned fire watch duties on a welding/cutting operation that was taking place on the floor above him.

Best Practices
 

  • Establish and discuss safe work procedures. Identify and control all hazards. Train all persons to recognize and understand safe job procedures before beginning work.
  • Always use fall protection when working where a fall hazard exists.
  • Protect openings near travelways through which persons may fall by installing appropriately designed railings, barriers, or covers.
  • Keep temporary access opening covers secured in place at all times when the opening is not being used. Replace deteriorated floor plating and grating.
  • Ensure that areas are barricaded or have warning signs posted at all approaches if hazards exist that are not immediately obvious.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf), Overview (powerpoint), Overview (pdf).

Fatality #12 for Metal/Nonmetal Mining 2012

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On August 17, 2012, a 58-year old equipment operator with 19 years of experience was killed at a cement operation. The victim was working on the roof of a 189-foot tall silo when the roof collapsed. Rescuers responded immediately and recovered the victim on September 4, 2012.

Best Practices
 

  • Routinely inspect the entire silo including walls, top, hopper(s), feeders, conveying equipment, liner, roof vents, etc. Look for structural damage, exposed rebar, stress cracks, corrosion, concrete spalling/cracking, signs of overfilling, top lifts, dust spills from seams during loading, damage to climbing devices, etc. The structure should be inspected by a professional engineer knowledgeable in silo design and construction.
  • Ensure a competent person conducts examinations to identify hazards.
  • If damage is discovered, prohibit use of and access on the silo and in the surrounding area until repairs are complete and/or a registered professional engineer has declared it structurally safe to use.
  • Modifications or equipment additions to a silo should be under the direction of a professional engineer.
  • Ensure process controls and dust collector baghouses are in working order to prevent overpressure, overfilling, or excessive vacuum. Dust leaving a silo may indicate structural damage or equipment malfunction.
  • Ensure aeration systems and other means of enhancing hopper flow are in working order so asymmetric flow patterns do not develop within the silo and damage the walls, hopper, and roof.
  • Provide silo level probes/weight measuring technology for /equipment to monitor silo material filling and discharge in the silo and keep it in working order.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf), Overview (powerpoint), Overview (pdf).

Fatality #11 for Metal/Nonmetal Mining 2012

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On August 31, 2012, a 49-year old driller with 24 years of mining experience was killed at an underground gold mine. The victim was assigned to prepare the work area to set up a long-hole bench drill and was working near an open stope when he fell down the stope. He was inadvertently loaded out with the material and transported by a haul truck to the surface where he was later discovered.

Best Practices
 

  • Always use fall protection with a lanyard anchored securely when working where there is a danger of falling.
  • Examine workplaces for changing conditions when the strata, drill patterns, or other workplace conditions change.
  • Establish policies and procedures for safely clearing hung or stuck material and ensure that persons follow those safe policies and procedures.
  • Ensure that persons are task-trained and understand the hazards associated with the work being performed.
  • Ensure that areas are barricaded or have warning signs posted at all approaches where hazards exist that are not immediately obvious.
  • Consider using a “miner in distress” call feature available on many communication and tracking systems carried by miners. This feature is designed to improve emergency response if a miner working alone or out of sight of other miners requires immediate assistance.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf), Overview (powerpoint), Overview (pdf).

Fatality #14 for Coal Mining 2012

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On September 11, 2012, at approximately 10:15 a.m., a fatal accident occurred while moving longwall equipment at the Drummond Company, Inc., Shoal Creek Mine. A 28 year old miner was killed when he was crushed between the coal rib and a large power center, weighing approximately 30 tons.

Best Practices
  • Prior to beginning any work activity, train the miners to perform the task-at-hand safely.
  • STAY OUT of areas where clearance is tight (pinch points) and visibility is limited when haulage equipment is being operated to move large equipment and/or components.
  • Ensure that equipment operators establish good communications between themselves and other miners that may be working around or near their equipment.
  • While moving equipment, ensure that all persons are located safely out of the route of travel, especially with limited visibility.
  • Ensure that all large equipment and/or components are secured adequately to prevent unintended motion when being moved.
  • Inspect the mine floor properly in areas where large equipment and/or components will be transported to identify any irregularities that may cause unexpected movement of the equipment and/or components being moved, or with the machinery being operated to move the equipment.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).