2002 Coal Fatalities

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2002 Coal Fatalities
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2001 Coal Fatalities As of September 16, 200222
Fatalities9 Surface13 Underground
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UndergroundClassification
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UndergroundOccupation
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UndergroundWork Activity
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SurfaceClassification
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SurfaceWork Activity
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SurfaceOccupation
9

• January 2, 2002, a 44-year old remote control
  continuous mining machine operator with 23 years
  of mining experience was fatally injured in a
  roof fall accident. The victim was mining in the
  No. 2 right crosscut of the 7 headgate section
  when roof rock measuring seven feet by five feet
  by three to five inches in thickness fell in the
  area where he was standing. The continuous mining
  machine had sheared off 7 roof bolts when
  starting this crosscut. The victim was operating
  the machine while under this unsupported roof at
  the time of the accident.

10

• Never work or travel under unsupported roof
• Hang reflectors or other warning devices prior to
  mining.
• When operating a continuous mining machine with a
  remote control, always maintain a safe distance
  between you and the machine.
• Know and follow the provisions of the approved
  roof control plan.
• Avoid damage to roof support systems.

11

• January 24, 2002, a 43 year old general inside
  laborer was fatally injured while performing
  electrical work on the 12,470 volt underground
  power center located on the 001-0 section. During
  retreat mining a length of high voltage cable was
  removed. Problems were encountered with
  re-energizing the power at the substation on the
  surface after the cable was re-stocked in the
  section power center. The certified electrician
  came outside to check on the problem. When power
  was restored to the section it was discovered
  that the phasing was wrong. Power was removed
  from the section to correct the phasing. The
  victim was working on the leads inside the power
  center when the 001-0 section power was again
  re-energized from the surface, resulting in a
  fatal electrical accident.

• Always lock and tag out before doing electrical
  work.
• Electrical work shall be performed by a qualified
  electrician or persons trained to do electrical
  work under the direct supervision of a qualified
  electrician.
• High voltage circuits must be grounded at all
  times while work is being performed.

12

• January, 31,2002, a miner with 11 years of mining
  experience was fatally injured when he was hit by
  a battery powered Stamler Uni-hauler. There were
  no eye-witnesses, however immediately prior to
  the accident, the victim was reportedly seen
  walking from the No. 5 entry toward the No. 4
  entry dragging a piece of ventilation curtain.
  The operator of the Stamler Uni-hauler had just
  pulled the equipment, battery end first, into the
  No. 4 entry in order to turn the equipment and
  start loading coal from the No. 5 entry. The
  victim was discovered a short time later, lying
  on the mine floor in the No. 4 entry, and
  entangled in the piece of ventilation curtain.

13

• Equipment operators should always insure that
  they maintain a safe distance between the
  equipment being operated and the other miners in
  the area.
• A warning should be sounded when the equipment
  operator's visibility is obstructed or when
  direction of travel is changed.
• Never position yourself in an area or location
  where equipment operators cannot readily see you.

14

• February 18, 2002 at approximately 250 P.M., a
  39 year old miner with 6 years and 10 months of
  mining experience was fatally injured by a roof
  fall. The victim was operating a single head
  "squirmer" type roof bolting machine installing
  42 inch fully grouted resin bolts in the face of
  number 6 entry of the 003 mining section when the
  fall occurred. The position of the roof bolting
  machine exposed him to unsupported roof. The
  victim was struck by a section of mine roof that
  measured approximately 21 feet by 19 feet 11
  inches by 13 to 16 inches thick.

• Never work or travel inby supported roof.
• Always know and follow your approved roof control
  plan which may have specialized provisions for
  certain bolting patterns.
• Always examine the roof, face and ribs
  immediately before any work is started and
  periodically as conditions warrant.

15

• February 20, 2002, a 53-year old roof bolting
  machine operator, while helping on the continuous
  mining machine, was fatally injured when he was
  struck by rock from an unintentional roof fall.
  The victim was helping the operator of the
  continuous miner tram the machine into the
  intersection after completing the last lift of
  the right pillar block located in the No.4 Entry
  of the 002-0 section. The roof in the
  intersection fell with little or no warning,
  resulting in fatal injuries to the roof bolt
  machine operator, and serious injuries to the
  mining machine operator. The fall, consisting of
  unconsolidated rock ranging from approximately 2
  to 10 feet thick, 30 feet long and 30 feet wide,
  covered the continuous mining machine and
  partially covered a coal hauler located behind
  the continuous mining machine.

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• Know and follow the provisions of the approved
  Roof Control Plan. Take additional measures to
  protect all persons if unusual hazards or
  conditions are encountered.
• Always examine the mine roof properly in your
  work area.
• Conduct proper pre shift and on shift
  examinations in all areas prior to mining.
• Always be alert for changing roof conditions.
• Never work or travel under unsupported roof.

17

• March 22, 2002, a 33 year old section foreman was
  fatally injured when he was caught between the
  conveyor boom of a continuous mining machine and
  the coal rib. The victim was using a remote
  control unit to tram the machine when he was
  struck by the end of the conveyor boom.

18

• Continuous mining machine operators should never
  be located between the machine and the coal rib
  while the machine is being trammed from place to
  place by remote control.
• When moving continuous mining machines around
  corners, or in other instances where the left and
  right traction drives are operated independently,
  low tram speed should be used.
• The pump motor should be de-energized, and all
  machine motion stopped, when the trailing cable
  or water line has to be repositioned in close
  proximity to the continuous mining machine

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• Wednesday, April 10, 2002, a 33 year old
  continuous mining machine operator, with
  approximately 9 years mining experience, was
  fatally injured in a roof fall accident. A rock
  measuring 4 to 16 inches thick, 100 inches long,
  and 65 inches wide fell from the mine roof
  pinning the miner operator against the shuttle
  car tire. The rock fell at the mouth of the No. 4
  right crosscut, from an area inby the last row of
  bolts, and cantilevered into the bolted area
  where the miner operator was standing.

• Miners must know and follow the approved roof
  control plan
• Reflectors should be used to warn persons of
  hazardous areas
• All miners should receive hazard recognition and
  safe work practice training

20

• May 11, 2002, a 46-year-old coal hauler operator
  was fatally injured when transporting coal from
  the face to the feeder in the Southwest Mains
  Section. As the operator was attempting to make a
  right turn into the crosscut between the number
  four and three entries, the left rear portion of
  the coal hauler frame pinched the Joy 14 BU
  loading machine trailing cable between the right
  inby rib and the coal hauler. This resulted in
  the frame of the rubber tired coal hauler
  becoming energized. The victim apparently exited
  the machine to check the pinch point, came into
  contact with the energized machine frame and was
  electrocuted.

21

• Provide ample clearance or protection for
  electrical cables located in haulage ways.
• Examine haulage ways prior to the start of
  loading to assure that all electrical cables are
  positioned to prevent them from being contacted
  by mobile equipment.
• Should the haulage machine accidentally pinch a
  power or trailing cable, the following procedures
  must be followed Stay in the vehicle you are
  operating DO NOT EXIT THE MACHINE !Make sure
  that all persons remain IN THE CLEAR OF THE
  DAMAGED CABLE AND MACHINE ! Attempt to move the
  machine away from the cable. If you cannot move
  the machine away from the pinched/damaged cable,
  have someone go to the power center to
  de-energize power to the pinched cable and your
  machine.

22

• May 21, 2002, a 50-year-old electrician with 30
  years of experience, was fatally injured in an
  electrical accident. The victim was working on a
  480 VAC distribution box that supplied power to a
  section battery charging station. Apparently, the
  victim came in contact with an energized bus bar
  located inside the distribution box.

• De-energize, lock and tag before doing electrical
  work, unless testing or troubleshooting
• Insure that all electrical circuits and circuit
  breakers are properly identified before
  troubleshooting or performing electrical work
• Insure that electrical work is preformed by
  qualified electricians or properly trained
  persons under the direct supervision of a
  qualified electrician
• Wear proper protective gloves to prevent injuries
  when electrical troubleshooting activities are
  being conducted

23

• June 20, 2002, a 55 year old utility man with 31
  years mining experience was found trapped between
  the frame of the number 12 bunker car and the
  upright beam attached to the catwalk that
  provided access to the bunker area. He was
  assigned to work on the old bunker in the "A"
  shaft area of the mine.

• Repairs or maintenance should not be performed on
  machinery until the machinery is blocked against
  motion.
• All power circuits and electrical equipment shall
  be de-energized before any work is performed on
  such equipment.

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• May 23, 2002, a 58-year-old electrician sustained
  serious injuries as a result of an electrical
  accident. The victim was located beside the
  section power center when an electrical arc at
  the female receptacle of a shuttle car occurred
  causing severe burns to the victim. According to
  statements obtained during interviews, the victim
  was attempting to find a fault in the shuttle car
  cable when the accident occurred. Following the
  accident, the victim remained hospitalized, until
  he died from his injuries on June 27, 2002.

• Always use proper diagnostic equipment while
  trouble shooting or testing.
• Insure that qualified electricians perform all
  electrical work or properly trained persons under
  direct supervision of a qualified electrician.
• Always wear protective gloves when performing
  tasks that may cause injuries to the hands.

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• August 12, 2002, at approximately 145 p.m., a 23
  year old miner was killed when his head was
  caught between the conveyor boom of the
  continuous mining machine and the mine roof. The
  continuous mining machine operator and victim
  were moving the mining machine from the working
  section to the surface for repairs. About half
  way to the surface, the front of the machine
  dropped over a small ledge in the mine floor
  causing the conveyor boom to strike the roof. The
  victim, who had been assisting with the
  continuous miner cable, was caught between the
  boom and roof. The victim's regular job title was
  greaser. He had 6 months and 10 days of mining
  experience.
• .

• Establish procedures for moving machinery and
  equipment.
• Assure that personnel do not position themselves
  in proximity to moving machinery.
• Maintain clear visibility with all personnel in
  the vicinity of moving equipment.
• Keep trailing cables on the operator's side of
  the machine when moving the machine.

26

• August 19, 2002, at approximately 900 p.m., a 29
  year-old construction worker, with two months
  experience, sustained fatal injuries from a rib
  roll approximately 1473 feet inby the portal of a
  slope-sinking operation. The victim was gathering
  tools in a plastic bucket to be transported to
  the surface when a rock measuring 8 1/2 feet in
  length by 3 feet in width by 2 feet thick rolled
  out from the rib causing fatal injuries.

• Always work and travel under supported roof and
  secure ribs.
• Apply additional safety precautions in areas
  where geological changes and anomalies in strata
  are present.
• Frequently test the roof and ribs with a sounding
  device.
• Scale loose materials using the proper equipment
  from a safe distance.
• Assure that sufficient bolt coverage occurs
  across roof/rib in non-rectangular openings.

27

• January 28, 2002, a clean coal filter drain pump
  exploded due to steam build up within the pump,
  inflicting fatal injuries to the fine coal
  operator at a preparation plant of an underground
  mine. The victim was standing approximately 8
  feet away at the on/off switch when the pump
  cover struck him. The pump overheated after
  almost all liquids had been pumped from the
  filter drain tank causing the remaining fines to
  solidify, thus preventing flow. The inlet and
  discharge lines then became clogged with coal
  fines causing the pump to become a closed
  pressure vessel.

• For pumps which may overheat due to loss of
  fluids or from cavitation
• Provide pump housing with thermal sensing device
  that will de-energize the circuit.
• Provide pump with remotely located on/off
  controls.
• Never de-energize an overheated pump from close
  proximity.
• Install cut-off valves or other devices to
  prohibit back-flow of water into overheated pumps.

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• February 20, 2002, a 49-year old miner was killed
  by a fall of rock from a highwall at a surface
  coal mine. The miner was operating a Caterpillar
  Model 834 rubber tire bulldozer, cleaning the pit
  floor at the No. 8 shovel, when rock and material
  fell from the highwall striking the bulldozer.
  The massive block of material crushed the cab
  causing fatal injuries. The bulldozer was
  equipped with a falling object protective
  structure (FOPS)/ rollover protective structure
  (ROPS), which was not sufficient to prevent fatal
  injury to the operator. The ROPS/FOPS and cab
  were removed during recovery operations and are
  not visible in the picture below.

• Highwalls and work areas should be thoroughly
  examined for hazardous conditions and any loose
  material should be scaled from the highwall.
• Mining systems should ensure that equipment
  operating personnel's work or travel areas are a
  safe distance from the toe of the highwall.
• Personnel should be thoroughly trained in the
  requirements of the company's ground control
  plan.

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• February 27, 2002, a 43-year old truck driver,
  employed by an independent trucking company, was
  fatally injured while loading an over-the-road
  haul truck at a surface load-out of an
  underground coal mine. The driver had loaded coal
  into both of the 20-ton, bottom-dump trailers
  that were connected to the truck, but coal had
  spilled over the side of the second trailer. The
  driver got out of the truck to check the
  spillage, setting the tractor brakes but not the
  trailer brakes. While he was outside, the truck
  began moving down the road that had an
  approximate 6 grade. The driver attempted to
  re-enter the truck and was thrown from the truck,
  and then hit by this same truck. The truck
  traveled approximately 200 feet before striking a
  hillside and coming to a rest. The driver had
  about one year of experience as a truck driver,
  and this was his first trip to the load-out where
  the accident occurred.

• Set all brakes before dismounting or leaving a
  truck.
• Know the truck's capabilities, operating ranges,
  load-limits and safety features.
• Provide hazard training for all new drivers at
  each mine site and load-out facility.
• Provide task training for all new task preformed
  by a miner.
• Block wheels to prevent movement when parking
  trucks on a steep grade.
• Know and understand safe self-loading procedures
  thoroughly.

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• April 26, 2002, a 61-year old mechanic/welder,
  with 16 years of mining experience, was fatally
  injured in a powered haulage accident while
  fueling a Caterpillar D11 bulldozer in the pit of
  a surface coal mine. While fueling the bulldozer,
  the victim's service truck began to roll away,
  down a 6-8 grade toward a Liebherr haul truck.
  The victim ran after the service truck, mounted
  the running board, and apparently slipped off and
  fell under the rear tandem wheels. The truck
  continued another 35 feet, struck the front of
  the Liebherr haul truck, and stopped. The service
  truck traveled approximately 225 feet before
  hitting the haul truck. Wheel chocks were found
  at the site. They appeared to have been used, but
  did not prevent the truck from moving downhill.

• Do not leave mobile equipment unattended unless
  the brakes are set.
• When mobile equipment is left unattended on a
  grade, turn the wheels into a bank or berm, or
  properly block them.
• During task training, emphasize proper methods of
  blocking the wheels of parked equipment.
• Perform tasks such as refueling on level ground,
  whenever possible.

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• June 28, 2002, at approximately 550 A.M., a
  49-year-old truck driver was fatally injured when
  the truck he was operating (a 50-ton 773B
  Caterpillar) backed through a haul road berm
  prior to reaching the dump point, the truck
  overturned and slid down a steep slope into a
  coal slurry impoundment. The driver was recovered
  from the impoundment at 125 P.M. and transported
  to a local medical facility where he was
  pronounced dead.

• Never allow vehicles to travel in reverse for
  extended distances when it is possible to travel
  forward.
• Clearly mark dump locations with reflectors
  and/or markers.
• Arrange dump locations such that drivers may use
  the driver's side mirrors for visibility while
  backing.
• Maintain proper berms along all haul roads.
• Maintain adequate illumination on trucks and/or
  dump sites.

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• July 10, 2002, a 44-year old mechanic/ truck
  driver, employed by an independent trucking
  company, was fatally injured while performing
  repair work on a coal haul truck. The
  transmission had become locked in gear and the
  mechanic was summoned to repair the truck. While
  attempting to free the transmission, the mechanic
  positioned himself under the truck to remove the
  drive shaft. When the drive shaft was removed,
  the truck rolled forward crushing the mechanic
  under the right rear set of tandem wheels. The
  parking brake had not been set and the truck had
  not been blocked to prevent movement (blocking
  shown was provided after the accident).

• Always set the parking brakes and block machinery
  against motion before repairs are performed.
• Know and follow safe work procedures before
  beginning repairs.
• Examine work areas before starting work.

33

• August 13, 2002 at approximately 300 a.m., a
  66-year-old highwall drill operator was fatally
  injured when he fell twenty-three feet off the
  edge of a highwall. The victim was walking from
  his truck along the drill bench to his highwall
  drill in dark and foggy conditions when the
  accident occurred. The victim was able to call
  for help using a cell phone. The victim was
  rescued, however, he later expired as a result of
  injuries.

• Provide and use appropriate lighting in work
  areas after dark.
• Establish and use designated travelways to travel
  to and from work areas.
• Always be aware of your surroundings and any
  hazards that may be present.

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August 27, 2002, a 40-year-old coal auger
operator died after he entered a 30-inch diameter
auger hole that he was drilling. The auger had
penetrated two previously drilled auger holes.
The victim entered the hole to determine the
angle and depth of the previously drilled holes.
The auger hole he entered had penetrated the coal
seam 144 feet. He was apparently overcome by the
lack of oxygen approximately 120 feet into the
hole. Two co-workers tried to rescue the victim
but became dizzy and had to exit the hole.

• Never enter an auger hole.
• Barricade, block or backfill auger holes to
  prevent unauthorized entry.

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August 30, 2002, a 34 year old truck driver was
fatally injured while operating a Volvo A30C
articulating truck. The victim had stopped the
truck to be loaded by an excavator when the truck
suddenly moved forward and over a steep
embankment. The truck traveled approximately 1000
feet down the slope and eventually came to rest
on the main haul road.

• Examine haulage equipment for safety defects
  before operation.
• Immediately report mechanical safety defects to
  mine management.
• Implement a preventive maintenance program for
  all haulage equipment. The maintenance program
  should be comprehensive enough to ensure that
  critical safety systems such as brakes and
  steering are operational at all times.
• Construct and maintain berms properly on the
  outer bank of all elevated roadways.

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MORE

• MORE

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December 17, 2001, at approximately 1150 a.m., a
surface machinery accident occurred which
resulted in fatal injuries to an Equipment
Operator. The victim was working toward the
installation of a de-watering pump along the
access road leading to the flooded 01 pit. The
work involved the use of a Model D6D Caterpillar
bulldozer along an approximate 13 grade. For
reasons unknown at this time, the machine
overturned. The bulldozer was found approximately
90 feet down the access road lying on its left
side with the victim pinned between the rollover
protection and the ground. There were no
eyewitnesses to the accident.

• Especially when operating machinery, workers
  should always be attentive to changes in ground
  conditions and visibility.
• All personnel, who operate mobile equipment,
  should be instructed to wear their seatbelts,
  where required, at all times when the equipment
  is in motion.
• Workers and mine management should always be
  alert to changing weather conditions and insure
  that proper examinations are made after every
  rain, freeze or thaw, prior to entering specified
  work areas.

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During 2001, eight explosions have occurred at
metal/nonmetal mining operations. These accidents
resulted in one fatality and nine nonfatal
injuries. MSHA believes each of these accidents
could have been prevented. We request that mine
operators reevaluate all work procedures now in
place regarding handling, storage or use of
explosive fuels or dust. We have compiled a brief
synopsis addressing each event gleaned from the
preliminary information reported to MSHA. This
information is not intended to replace the
investigation findings pertaining to these
accidents.
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February 7, 2001- An explosion occurred in the
dust collector for the pulverized coal fuel
system at a cement operation in Virginia.
Temperature spikes reached 170 degrees Fahrenheit
which indicated problems in the coal grinding
mill. Subsequently, hot embers were transported
from the coal mill through the cyclone into the
dust collector bag house where they initiated the
explosion.
February 8, 2001- An explosion occurred in the
kiln at a cement operation in Pennsylvania. Two
natural gas lines were lit and inserted into the
kiln during the pre-heat, start-up procedure.
After it was determined that the flames appeared
to be extinguished, one of the lines was removed
and relit. As the line was being reinserted into
the kiln, it ignited the accumulation of gas.
40
March 20, 2001- An explosion occurred inside an
enclosed weigh scale sump at a crushed stone
operation in Wisconsin. A lit, hand-held propane
torch had been placed inside the sump to thaw a
build up of ice. The flame extinguished, allowing
an explosive mixture of gases to accumulate. When
a second lit torch was placed in the sump, it
ignited the explosive gases.
April 2, 2001- An explosion occurred in the coal
grinding mill at a cement operation in Alabama.
The explosion, which was initiated by hot embers
generated in the coal mill, damaged the grinding
mill, the cyclone and the duct work of the
pulverized coal feed system.
May 3, 2001- An explosion occurred in a transfer
chute at a cement operation in California. The
access door had been opened and a miner was
removing built-up material with an air lance. It
is believed that the metal to metal contact
generated by the air lance on the side of the
chute provided the ignition source that ignited
the coal dust.
41
May 19, 2001- An explosion occurred in a kiln at
a clay operation in Texas. The kiln had been
taken off- line and several repairmen had entered
it to perform maintenance. As the repair was
being done, an accumulation of organic dust fell
and traveled through the piping into the
combustion chamber where it was ignited by hot
material.
May 30, 2001- An explosion occurred in the
storage bin of the indirect fired, pulverized
coal feed system at a cement plant in Virginia. A
fire was detected in the bin and carbon dioxide
was introduced into the closed system. The coal
feed was stopped and the bin was emptied. When
the coal feed was restarted, hot embers remaining
in the bin ignited the coal dust.
May 31, 2001- An explosion occurred in a kiln at
a cement operation in Missouri. Propane was being
used to pre-heat the kiln during the start-up
procedure. The flame extinguished and the kiln
filled with gas which was subsequently ignited.