SAFE MAINTENANCE & REPAIR

ACTIVITIES
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.
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
 ELECTRICAL MECHANICAL
Electrical Shock Caught in Moving
Thermal Arc Flash Machinery
Burns Serious Injuries
Thermal Blowouts Disabling Injuries
Disabling Injuries Loss of Limb
DEATH
ELECTROCUTION
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
Does Your Company have a
Lockout/Tag & Block Policy?
Is it...
In writing, verbal?
Positive & effective?
In miners training classes?
Enforced by mgmt.?

Is it blocked against

hazardous motion ?
Did YOU take the Keys?
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?
OJTd?
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)
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.
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.
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.
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.
Blocking Against Motion
In 20067 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 cant kick out or slip.
Install props permanently on mobile &
stationary equip so they are available.
 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.
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.
Dont use damaged, poorly spliced, worn or
undersized cables. Includes both cables!
Dont wrap the cables around your body.
Dont touch the energized stinger with bare-hand.
Turn off welder when not in use.
Avoid wet conditions. Use appropriate safeguards.
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.
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.
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.
Working on Pressurized
Fittings..
A miner injuredattempted 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.
Working on Pressurized
Fittings
Dont 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)
Large Wheel/Tire Assemblies
Many miners killed/seriously injured over
the years.
Dont work on them w/o safety cage or other
restraining device.
Dont stand too close during inflation/deflation.
Dont hit inflated wheel/tire assembly with a
hammer.
Dont weld rims on wheel/tire assembly.
Dont use mismatched rim parts
Always wear eye protection.
 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
THINK THE JOB OUTBEFORE
YOU BEGIN WORK !

What about the following miners?

 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.
 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.
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.
 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).
 4 MINERS

4 miners have been electrocuted

since 1999 performing welding
operations. (wet clothing/ wet
environments and current are a
deadly combination)