Michigan State Grants Mine Safety Training Newsletter 98-3 Program Updates Safety Concerns - Carbon Monoxide Combustion Emissions New Mine Operator Concerns Toxic Release Inventory Reporting New HazMat Transport Rule on the Way News about MSHA Personal Accountability in Citations Underground Diesel Emissions Concerns OSHA Items of Interest to Mines Printing Company to Pay for Unsafe Practices Crane Safety You're the Inspector- How Do You Fare? Holmes Association Meetings Announced Manager - Dave Carlson 906/487-2453, Email dcarlson@mtu.edu Mining Engineering Department Mary Ewert - Clerk 906/487-2272 Michigan Technological University Program Director/Department Chair - Francis Otuonye 906/487-2610 Houghton, MI 49931 Internet Home Page - http://www.mm.mtu.edu/mine_safety/mine.html Contact Dave Carlson at the phone number listed above for assistance with setting up a safety training workshop. Contact Mary Ewert for locating suitable videos and other training materials or handouts for your in-house workshops. If we can't answer your safety-related questions we will find out or put you in touch with someone who can. See our internet home page at the address listed above. Program Updates Program personnel are completing a version of Mine Safety Jeopardy for use in training, especially during periods when trainee interest tends to wane. Using the game will require a computer (preferably a laptop) with either Microsoft Powerpoint installed or one that has access to the Internet. During the next two months, we also hope to complete our manual of questions and answers on various mine safety topics. Safety Concerns Carbon Monoxide Combustion Emissions Safety Whenever fuel is burned, the carbon in the fuel is chemically converted to carbon dioxide in the exhaust. A small percentage of the fuel carbon does not combust completely to carbon dioxide, but ends up as deadly carbon monoxide and as other carbon compounds. The fraction of fuel carbon ending up as carbon monoxide depends on the combustion conditions. At surface mines, carbon monoxide is generated by engines and various heating systems. It is often erroneously assumed that diesel exhaust and exhaust from propane-powered engines or heating systems do not contain dangerously-high carbon monoxide concentrations. While these concentrations are lower than those from a typical gasoline engine, similar precautions are essential. A dirty air cleaner on an engine will restrict the oxygen needed for combustion and increase carbon monoxide emissions. Engine settings also affect carbon monoxide emissions. In our tailpipe measurements on underground diesel equipment we have found high-enough carbon monoxide concen-trations out the tailpipe to kill a person taking one or two breaths. Diesel and propane emissions, in a confined space such as an enclosed garage, must always be viewed as a life-threatening concern, even when produced for only short time intervals. Combustion in an unvented confined space is always dangerous, regardless of how low the concentration of carbon monoxide in the emissions. Not only is there danger of abnormally-high emissions due to unknown conditions, but as combustion continues, the oxygen concentration decreases in the confined space and, therefore, in the intake air. Combustion sources of concern in mines include diesel and propane-powered engines and non-vented propane heaters. The oxygen is needed to combust the fuel and this decrease in oxygen concentration results in incomplete combustion and the production of abnormally-high carbon monoxide emissions. As oxygen in the confined space is used and continues to decrease, carbon monoxide increases exponentially and an otherwise-safe combustion source becomes a critical threat to life. Because of this decreased-oxygen/increased carbon monoxide concern, unvented propane heaters should always come equipped with sensors that shut them off before the oxygen concentration is low enough to significantly affect combustion. These sensors greatly improve safety. However, the choice between vented and unvented should still weigh heavily on the side of well-vented in our estimation. In addition to the imminent-danger threat, other products of combustion may, over time, seriously affect the health of those exposed. New Mine Operator Concerns Toxic Release Inventory Reporting Are you producing one of 650 specifically-identified toxic chemicals on EPA's list? EPA will require 1998 results by July 1, 1999. Regulations are found in 40 CFR Part 372. The rule extending reporting requirements to mining facilities was published in the May 1, 1997 Federal Register at 62 Fed. Reg. 23834. Guidance documents, including guidance specifically developed for metal mining and coal mining facilities, can be obtained through the EPCRA/Superfund Hotline at 800/535-0202 and are on the Internet at www.epa.gov/opptintr/tri/industry.htm. A home page with links to TRI documents is at www.epa.gov/epaoswer/hotline/. New HazMat Transport Rule on the Way The January 8, 1998 Federal Register published a rule which requires that in-state shippers of hazardous materials comply with the same rules that apply to shipments across state solar protection factor of at least 15. News About MSHA Personal Accountability in Citations MSHA issued 567 unwarrantable failure citations and orders in Metal/Nonmetal mines in FY 97 compared to 323 in FY 96. Personal fines against foremen and managers increased from 110 in FY 96 to 167 in FY 97. Two unrelated coal mining companies and four individuals were indicted in November 1997 for willfully violating mine safety standards, making false statements, and in one case for covering up material facts. The indictments arose out of MSHA investigations of fatal roof falls. In one case, individual defendants were charged with falsifying the weekly examinations record book, concealing material facts from MSHA, submitting false documents to MSHA, falsifying the pre-shift daily report record book, and willfully failing to conduct an adequate pre-shift examination. In the other case, the individuals were charged with willfully violating mandatory safety standards by failing to conduct adequate on-shift examinations, failing to prevent persons from traveling inby permanent roof support, failing to follow approved roof control plans, using hazardous pillar recovery methods, failing to conduct an adequate pre-shift examination, and falsifying the daily report record book. If convicted, the two corporations face maximum fines of $4.5 and $8.5 million. The individuals face maximum prison sentences ranging from seven to 61 years and maximum fines ranging from $450,000 to $3.1 million. Underground Diesel Emissions Concerns A rule proposed April 9 by MSHA for underground diesel use in coal mines does not set a TLV for diesel particulate matter, but requires the use of technology to remove 95%. In a draft report issued in March, EPA reaffirmed an earlier determination that diesel exhaust is a probable human carcinogen. EPA's finding has been vigorously challenged because it is based upon epidemiological data of questionable validity. OSHA Items of Interest to Mines Printing Company to Pay for Unsafe Practices Creative Response, Inc., a printing company in Wood-Ridge, N.J., was fined $156,800 for alleged violations - five willful, fifteen serious and three other-than-serious. Willful violations at the Wood-Ridge headquarters and at the Carlstadt, N.J., facility include failure to properly guard points of operation of machinery and failure to properly guard drive gears on machinery. Serious violations include failure to keep exits clear and failure to establish a hearing protection program. Creative Response has until July 16 to contest the citations. Crane Safety A review by OSHA of 400 crane incidents in general industry and construction over a 5-year period identified 354 fatalities or an average of 71 per year. OSHA's analysis identified the major causes of crane accidents as: boom or crane contact with energized power lines (nearly 45% of the cases), overturned cranes, dropped loads, boom collapse, crushing by the counter weight, outrigger use, falls, and rigging failures. Crane manufacturers supply specifications within which a crane may be used safely, including load capacity and operading speeds. OSHA's standard (29 CFR Part 1926.550) adds guarding to prevent employee contact with moving parts, safety glass or equivalent for cab windows, and guardrails and handholds. OSHA forbids employer modifications or additions affecting capacity or safe operation without written approval by the manufacturer. The OSHA standard requires inspection prior to each use, and during use as well as repair of deficiencies. Wire ropes are subject to constant wear and tear and are apt to need replacement. OSHA also requires a thorough annual inspection covering the 1) Operators cab - general requirements, all control mechanisms, engine, and machinery, 2) Rope and rope accessories - spooling, ropes and fitting, pendants, and sockets, and 3) Cast and weld structures - revolving frame, boom, jib, counterweight, and lower works. The employer must maintain a record of inspection dates and findings. Modern cranes are said to be easier to use, but less forgiving of operator errors, so operator training is essential. One construction company uses the following outline for its training, which operators are tested on and must pass to gain approval to operate: Pre-start inspection and service Engine start-up Testing operating controls Traveling Operating Coordination and depth perception Returning, stopping, and securing. Contractors can protect themselves from liability concerns somewhat by requiring that operators be certified by the National Commission for Certification of Crane Operators. Contact with overhead power lines exposes boom truck and mobile crane personnel differently. The boom truck operator is at risk of electrocution because of direct contact with the ground through the controls. The mobile equipment crane operator is insulated from the ground and riggers and other workers on the ground are at greater risk. It is recommended that utility lines be either de-energized or moved beyond the safe working clear distance and this may require several weeks advance notice to the power company. In the event of power line contact, the operator should: 1. Stay in an isolated cab. Do not leave unless you are in extreme danger. If you must leave jump away from the equipment, landing with both feet together. Touching the equipment after landing will electrocute you. The ground around the crane may be charged so taking long strides may also electrocute you. Therefore shuffle your feet away from the equipment in very small steps. Otherwise large voltage difference between your feet will cause current flow from one foot and through you to the other foot and back to the earth. 2. It is extremely dangerous and not recommended to attempt to rescue a victim of electrocution without the current turned off. A victim of electrocution will probably require CPR and emergency medical care to restart the heart. Crane overloading and unstable ground account for most tipping incidents. Where unstable ground is a concern, blocking under the outrigger floats may be needed. You're the Inspector -- How Would You Fare in an Inspection Based on Last Year's Most Cited Violations (Marquette Office)? If the Answer to Any of the Following is "No", the Condition Needs Immediate Correction. 1. Are all moving machine parts guarded to protect persons from contacting gears, sprockets, chains, drive, head, tail,and takeup pulleys, flywheels, couplings, shafts, fan blades, and similar moving parts that can cause injury? 2. Are defects on equipment, machinery, and tools that affect safety corrected in a timely manner? 3. Are workplaces, passageways, storerooms, and service rooms kept clean and orderly? 4. Are safe means of access provided and maintained to all working places? 5. Are continuity and resistance of grounding systems tested immediately after installation, repair, and modification; and annually thereafter? Is a record of the resistance measured during the most recent tests available? 6. Are crossovers, elevated walkways, elevated ramps, and stairways of substantial construction, provided with handrails, and maintained in good condition? Are toeboards provided where necessary? 7. Are mobile equipment parking brakes capable of holding the equipment with its typical load on the maximum grade it travels? 8. Are manually-operated horns or other audible warning devices maintained in functional condition? 9. Are scaffolds and working platforms of substantial construction, provided with handrails and maintained in good condition? Are floor boards laid properly and do employees know and abide by the maximum safe load? Are working platforms provided with toeboards when necessary? 10. Are safety belts and lines worn when persons work where there is danger of falling? Does a second person tend the lifeline when bins, tanks, or other dangerous areas are entered? 11. Are berms or guardrails provided and maintained on the banks of roadways where a drop-off exists of sufficient grade or depth to cause a vehicle to overturn or endanger persons in equipment? 12. Are power wires and cables insulated adequately where they pass into or out of electrical compartments (all electrical wires)? Do cables enter metal frames of motors, splice boxes, and electrical compartments only through proper fittings? Are the holes through metal frames through which insulated wires (other than cables) pass substantially bushed with insulated bushings? 13. Is all metal enclosing or encasing electrical circuits grounded or provided with equivalent protection (other than battery-operated equipment)? 14. Are potentially-dangerous conditions corrected before equipment or wiring is energized? 15. Are inspection and cover plates on electrical equipment and junction boxes kept in place at all times except during testing or repairs? 16. Are openings above, below, or near travelways through which persons or materials may fall protected by railings, barriers, or covers, or where impractical to install such protective devices, are adequate warning signals installed? 17. Are principal power switches labeled to show which units they control, where identification cannot be made readily by location? 18. Are the controls of mobile equipment placed in the park position with the parking brake set when left unattended? Are the wheels or tracks chocked or turned into a bank when parked on a grade? 19. Are adequate first-aid materials, including stretchers and blankets provided at places convenient to all working areas? Are water or neutralizing agents available where corrosive chemicals or other harmful substances are stored, handled, or used? 20. Are compressed and liquid gas cylinders secured in a safe manner? 21. Has MSHA been notified of the date you plan to start your operation including the mine name, location, company name, mailing address, person in charge and whether operations will be continuous or intermittent? If you have closed a mine, has MSHA been notified with the same information indicating whether the closure is temporary or permanent? 22. Are seat belts worn by equipment operators other than when operating graders from a standing position where the operator wears safety lines and a harness in place of a seat belt? 23. Is firefighting equipment inspected according to the following schedules: (a) Fire extinguishers visually at least once a month to determine that they are fully charged and operable? (b) Maintenance checks made once every 12 months of: mechanical parts, the amount and condition of extinguishing agent and expellant, and the condition of the hose, nozzle, and vessel to determine that the fire extinguishers will operate effectively? 24. Are portable extension lights, and other lights that by their location present a shock or burn hazard, guarded? 25. Are waste or rags containing flammable or combustible liquids that could create a fire hazard either disposed of properly or in covered metal containers or other equivalent containers with flame containment characteristics? 26. Do all employees meet the 90 dBA, 8 hour slow response sound level and other conditions in 30 CFR part 56.5050? Is proper PPE provided and used to reduce excessive levels? 26. Does mobile equipment with an obstructed rear view have: (i) An automatic reverse-activated signal alarm; (ii) A wheel-mounted bell alarm which sounds at least once for each three feet of reverse movement; (iii) A discriminating backup alarm that covers the area of obstructed view; or (iv) An observer to signal when it is safe to back up? 27. Do conveyors, the entire length of which is not visible from the starting switch, have a system which provides visible or audible warning that is operated to warn persons that the conveyor will be started? Is the conveyor started within 30 seconds after the warning is given or a second warning given? 28. Are valves on compressed gas cylinders protected by covers when being transported or stored, and by a safe location when the cylinders are in use? 29. Does a competent person examine each working place at least once each shift for conditions which may adversely affect safety or health? Is prompt appropriate action to correct such conditions taken? 30. Is a record that such examinations were conducted kept by the operator and available to MSHA for a period of one year? 31. Is an individual capable of providing first aid available on all shifts who is currently trained and has the skills to perform patient assessment and artificial respiration; control bleeding; and treat shock, wounds, burns, and musculoskeletal injuries? Is first aid training made available to all interested miners? 32. Are toilet facilities provided at locations that are compatible with the mine operations and readily accessible to personnel? 33. Are readily-visible signs prohibiting smoking and open flames posted where a fire or explosion hazard exists? Holmes Association Meetings Announced Two upcoming meetings of the Great Lakes District Council of the Holmes Safety Association have been announced. The summer meeting and plant tour will be held Thursday August 27 in Milan, MI. The tentative agenda calls for one or more guest speakers during the morning meeting, lunch, and a tour of the London Aggregates Milan Quarry to follow. The Annual Meeting is being planned for the first part of October at Hidden Valley in Gaylord, MI. The tentative date is Tuesday, October 6. This meeting is a day-long workshop covering several safety topics that should be of interest to miners, and is open to anyone interested in safety. For more details, call Ken Cunningham at 517/792-8734.