the objective of this training program is to highlight the risk and hazards in maintenance activities

1. SAFE MAINTENANCE & REPAIR
ACTIVITIES

2. Maintenance Work: A Life or
Death Experience
EACH YEAR: MINERS DOING
MAINTENANCE & REPAIR WORK are
severely injured or killed from a wide variety
of HAZARDS, including:
ELECTRICITY (Shock, Burns & Electrocution),
INADVERTENT MOVEMENT OF MACHINERY
OR EQUIPMENT, AND
FALLING OFF PLATFORMS OR RAISED
AREAS.

3. Life's too precious for anything
less!!!
 All miners expect to return home after the end of
their shift. And their families expect them too.
 Analyze all aspects of the job before beginning
work.
 All hazards associated with the job should be
properly communicated to the miners before
starting work.
 Analyze every job… every day.
 45% of fatals in 2002 involved maintenance/repair
activities.
 46% in 2003. 48% in 2004 56% in 2005 50% in 2006

4.  ELECTRICAL
 Electrical Shock
 Thermal Arc Flash
Burns
 Thermal Blowouts
 Disabling Injuries
 ELECTROCUTION
 MECHANICAL
 Caught in Moving
Machinery
 Serious Injuries
 Disabling Injuries
 Loss of Limb
 DEATH

5. Working on electrically-powered equipment.
Deenergized, locked and tagged
- removed only by who installed
Work on power circuits.
Deenergized, locked and tagged
- removed only by who installed
- hot work only by equipped and qualified
Procedures during repairs or maintenance.
Off, locked and blocked

6. Does Your Company have a
“Lockout/Tag & Block” Policy?
Is it…...
In writing, verbal?
Positive & effective?
In miner’s training classes?
Enforced by mgmt.?
Is it blocked against
hazardous motion ?
Did YOU take the Keys?


7. Who does maintenance &
repair work at your mine?
You Must Care About It! Take interest!
Mechanical/Electrical/Welding (Good/So-so/Poor)
– Are they……..
– Qualified? Certified? Formally Trained?
– OJT’d?
– “Jack-of-all-trades”- The “shade-tree” type?
– “Know it all”?
– Who does it?…Equipment/Plant Operators? Laborers?
– Utility workers?
– Anyone? (that can hold a hammer/wrench)

8. What are things YOU can do?
 Establish safe work procedures:
 Incorporate manufacturer's
recommendations
 Assure workers are not exposed to hazards
when performing maintenance or repair.
 Identify ALL the hazards and correct
them…… before starting the work.

9. More things YOU can do….
Ensure that all workers are task trained.
Keep training up-to-date & current.
Ensure all workers follow established
safe work procedures.
Analyze the job before starting work.
Prior to beginning work, clear the area of
trip and fall hazards.

10. More things YOU can do…
Provide safe access to all work areas.
List the work steps.
De-energize, lockout and tag electrical
equipment… and mechanical equip.
Solidly secure/block/chock all applicable
equipment against movement - prior to
maintenance & repair work.

11. More things YOU can do…
Use appropriate fall protection where
there is a danger of falling.
Avoid pinch points.
Position your body/hands properly.
Stay focused for your own safety and for
the safety of your fellow workers.
Double check everything yourself, if
necessary.

12. Blocking Against Motion
In 2006…7 Miners Killed.
Safety props not used or ineffective.
All were PREVENTABLE!
Size the prop correctly.
Attach prop to ensure it can handle load.
Place prop so it can’t kick out or slip.
Install props permanently on mobile &
stationary equip so they are available.

13. WELDING
HAZARDS
 Electrical shock from welding can KILL!
 ANY welder, AC or DC has the power to
cause electrocution…..How?
If the current travels through you while you
are GROUNDED.

14. Some Safe Welding Tips
 Use dry, insulated gloves & protective
clothing.(change them to keep dry)
 Insulate yourself from the workpiece.
 Use fully insulated stinger. In good repair.
 Don’t use damaged, poorly spliced, worn or
undersized cables…. Includes both cables!
 Don’t wrap the cables around your body.
 Don’t touch the energized stinger with bare-hand.
 Turn off welder when not in use.
 Avoid wet conditions. Use appropriate safeguards.

15. What about Oxygen/Acetylene
Safety?
Always  your welding equipment before
cutting or welding operations.
Always  that valves at the torch are closed
before turning on the gas regulator valves.
Always  equip for wear/damage; leaks.
Always have good ventilation to work area.
Always wear correct clothing and PPE.
Always light the torch away from body.
Always keep grease/oil away from oxy lines.

16. Lubrication Systems
Automated lube systems (Octopus). Grease
pump & distribution lines.
Centralized lube system. Lever gun supplies
lube to single grease & on to others in system.
Extended grease fittings.
Single point auto lube - lube single point for
weeks or months at a time. Replace single
point lubricator when needed.
Provide catwalks or other safe access points.

17. Working on High Pressure
Hoses
Before working on system…….
Always shut down the pump(s), lock out
and tag.
Check hose(s) to be replaced by twisting
and squeezing for pressure relief, or other
preferred method.
If pressure still present…..take action to
relieve the pressure before loosening the
fittings.

18. Working on Pressurized
Fittings…..
A miner injured…attempted to bleed pressure
from a conveyor grease jack.
Jack had OEM relief type fitting broken.
Was replaced with a standard grease fitting.
Using 1/4” socket/ratchet the grease fitting
blew out of the jack as it was loosened. Like
a gun.
Always use the proper valves/fittings to
relieve grease pressure before maintenance.

19. Working on Pressurized
Fittings……
Don’t use a nail or wire to push in the ball on
a standard grease fitting to relieve pressure.
Pressure can be more than 10,000 PSI
Grease can shoot out in thin stream and inject
itself into your skin.
Grease is extremely poisonous when injected
into tissue and could require amputation.
(1 miner in Colorado knows this)

20. Large Wheel/Tire Assemblies
 Many miners killed/seriously injured over
the years.
– Don’t work on them w/o safety cage or other
restraining device.
– Don’t stand too close during inflation/deflation.
– Don’t hit inflated wheel/tire assembly with a
hammer.
– Don’t weld rims on wheel/tire assembly.
– Don’t use mismatched rim parts
– Always wear eye protection.

21. Whenever entering a bin or
hopper
Someone else must be outside
A life line or tagline must connect the two
The person outside must be healthy enough
to be able to assist if the person inside gets
into trouble

22. THINK THE JOB OUT…BEFORE
YOU BEGIN WORK !
 What about the following miners?

23. MINER #1
 Fatally burned while air gouging a
metal flange near a scrubber
opening.
– An ignition occurred after hot slag
contacted a combustible membrane in
the scrubber.

24. MINER #2
 A supervisor fell 9 feet from an
elevated area at a cement plant.
– A chain across a ladder opening
unhooked when he contacted it.

25. ALERT - Use of Chains to
Protect From Fall Hazards
Miners and managers should inspect
anywhere chains are provided to protect
persons from fall hazards.
Identify and promptly correct the
connection between the chain and the
permanent termination point.
A chain can easily slide out of the hook
when a horizontal force estimated at less
than 20 lbs. is applied:
 Re: Miner #2 accident.

26. MINER #3
 A miner was fatally injured when he
fell through a cover on a raised
structure (transfer house).
– He was repairing a water line and
stepped on a metal covering that failed
(rusted through).

27. 4 MINERS
 4 miners have been electrocuted
since 1999 performing welding
operations. (wet clothing/ wet
environments and current are a
deadly combination)