Machinery

Fatality #16 for Metal/Nonmetal Mining 2011

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On December 15, 2011, a 22 year-old laborer with 3 months of experience was killed at a surface stone operation. The victim, who was last seen on a control tower, fell into an operating jaw crusher.

Best Practices
 

  • Always use fall protection when working where a fall hazard exists.
  • Establish policies and procedures for safely clearing plugged material in a jaw crusher.
  • Ensure that persons are task trained and understand the hazards associated with the work being performed.
  • Deenergize and Lock-out/tag-out all power sources before working on crushers.
  • Do not place yourself in a position that will expose you to hazards.
  • 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 #21 for Coal Mining 2011

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On Wednesday, November 2, 2011, a 28 year old bulldozer operator, with approximately 8 years of mining experience, was injured at a surface mine. The victim was conducting reclamation work on top of a graded slope when he lost control of the bulldozer and it rolled over several times, approximately 250 feet to the bottom of the slope. The operator was wearing a seat belt, but sustained serious injuries. He was hospitalized and died subsequently on November 14, 2011.

Best Practices

  • Task train miners adequately on the equipment they will operate.
  • Train all employees on proper equipment operation procedures, hazard recognition, and hazard avoidance.
  • Establish and follow safe work procedures and ensure that personnel are trained to recognize hazardous work procedures or activity.
  • Be familiar with your work environment. Before you start grading an area, look at it, walk around it, and plan the safest way to move the material and maneuver the equipment.
  • Install tilt gauges in dozers and do not exceed the equipment’s maximum operating angles.
  • Maintain control of equipment at all times during operation.
  • Ensure that personnel operating mobile equipment always wear seat belts.
Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

Fatality #13 for Metal/Nonmetal Mining 2011

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On November 7, 2011, an 82 year-old owner/crusher operator with 27 years of experience was killed at a surface crushed stone operation. The victim was attempting to dislodge material from the vibrating feed hopper when he slipped or fell into the operating jaw crusher.

Best Practices

  • Establish policies and procedures for safely clearing plugged material in a feed hopper. Evaluate design modifications or use auxiliary equipment to reduce the risks associated with clearing an obstruction.
  • Ensure that persons are task trained and understand the hazards associated with the work being performed.
  • Deenergize and Lock-out/tag-out all power sources before working on crushers.
  • Provide and maintain a safe means of access to all working places.
Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report(pdf), Overview(powerpoint), Overview (pdf).

Fatality #17 for Coal Mining 2011

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On Monday, October 17, 2011, a 62-year old miner was killed on the surface of the underground mine while using a jumper cable to move a track-mounted back hoe machine at a gap in the trolley wire. When reenergized by a jumper cable, the machine struck and ran over him. The victim had 30 years of mining experience, with one day of experience operating this machine.

Best Practices

  • Assure all tram control switches are in the off position and the brake is set before applying a DC power jumper to the machine.
  • Always attach a nip on the machine first, then attach the nip on trolley wire, while standing in a safe location.
  • Ensure adequate task training is provided to equipment operators which cover all machine controls, functions and hazards related to the machine operation and any safe operating procedures related to the specific equipment operation.
  • Use self-centering tram/power controls to limit unexpected machine movement.
Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

Fatality #15 for Coal Mining 2011

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On Thursday September 1, 2011, a 29-year-old contract driller with 1 year, 3 months of experience was killed at a surface coal mine. The victim was attempting to separate a pipe connection when he was struck by a tong wrench. The rig was being used to drill a water well. The crew was working to free the drill stem that was stuck in the drill hole when the accident occurred.

Best Practices
  • Stand a safe distance from areas of potential high energy release.
  • Know the radius of machinery that pivots.
  • Establish and follow safe work procedures.
  • Ensure all components are adequately blocked and secured to prevent unintended motion.
  • Know the limitations of equipment used for blocking motion and ensure that they are used within their specified limitations.
  • Ensure all components are in good repair.
  • Establish and follow communication procedures.
Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

Fatality #13 for Coal Mining 2011

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On Monday, August 8, 2011, a 41-year-old longwall mechanic with nine years of mining experience was killed when he was struck in the chest by a piece of metal from the top of a base lift jack mounted on a longwall shield. The jack catastrophically failed resulting in the end cap separating from the cylinder and striking the victim.

Best Practices

  • Do not alter hydraulic circuits in a manner that could result in the trapping of pressurized hydraulic fluid.
  • When isolating hydraulic components for repair, ensure that the hydraulic system has a means to bleed the pressure from the components being repaired.
  • Evaluate potential energy sources before working in tight spaces. Click on the following link for more information: MSHA – SLAM Risks the Smart Way – Safety and Health Outreach Program Home Page
  • Ensure re-built components meet original equipment manufacturer (OEM) specifications.
  • Ensure miners are adequately trained in proper maintenance procedures and plan requirements.
  • Examine and periodically inspect all hydraulic components for defects.
  • Ensure the ratings of hydraulic components are compatible with their intended use.
Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

Fatality #5 for Coal Mining 2011

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On Saturday, May 14, 2011, a 37-year old mechanic with 14 years of mining experience and 1½ years of experience as a mechanic, was killed while removing a counter weight fuel tank assembly from a front-end loader. He was positioned beneath the front-end loader when he removed 14 of the 16 mounting bolts that secure the counter weight. When the victim attempted to remove the next to last bolt, the remaining two bolts failed allowing the 11,685 pound counterweight to fall on him. The counter weight had not been blocked to prevent it from falling.

Best Practices
  • Install blocking materials before removing mounting bolts from machinery components which can fall during disassembly.
  • Follow known safe maintenance procedures.
  • Follow the equipment manufacturers recommended maintenance procedures when performing repairs to machinery.
  • Train new mechanics in the health and safety aspects and safe work procedures related to their assigned tasks.

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

Fatality #4 for Coal Mining 2011

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On Friday, March 25, 2011, a 54-year old continuous mining machine operator with 35 years of experience was killed when he was caught between the coal rib and the conveyor boom of the remote controlled continuous mining machine he was operating.

Best Practices
  • AVOID “RED ZONES”!!! Prior to tramming the continuous mining machine to a new place, ensure the machine operator is positioned outside the turning radius of the machine. MSHA Red Zone webcast (pdf)
  • Prior to tramming the continuous mining machine to a new place, ensure the tip of the conveyor boom is positioned on the side of the mining machine opposite to the side where the machine operator is located.
  • Install MSHA approved Proximity Detection Systems on continuous mining machines. Proximity Detection Single Source
  • Assign another miner to assist the continuous mining machine operator. Train all persons in the programs, policies, and procedures for operating or working near remote controlled continuous mining machines. Additional information on preventing these types of accidents can be found at: MSHA’s Safety Targets Program Hit By Underground Equipment.

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

NIOSH Lock-Out Tag-Out Publication

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NIOSH has issued a new Workplace Solutions publication on Using Lockout and Tagout Proceduresto Prevent Injury and Death during Machine Maintenance. The four page publication reviews the exposure of the hazard in OSHA industries and the OSHA Standard. It examines a case report of a fatality involving a Millwright and lists recommendations for employers, workers, and manufacturers. You can download a copy in pdf format here.

Fatality #3 for Coal Mining 2011

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On Friday, February 11, 2011, a 55 year old miner with 30 years of mining experience was killed when the fuel and grease service truck he was operating collided head on with a scraper. The two pieces of equipment were traveling in opposite directions. The impact resulted in a fire that engulfed the fuel truck.

Best Practices

  • Inform others when driving a vehicle into a work area.
  • Optimize traffic rules to maximize safe road travel.
  • Obey established traffic rules and signage that apply to the area.
  • Follow established communication procedures.
  • Ensure signage is in place and easily observed.
  • Maintain control of equipment at all times.
  • Ensure all safety systems are maintained, including brakes and steering.

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