SAFE MAINTENANCE & REPAIR ACTIVITIES

1. FOCUS ON SAFE WORK FOR LIFE 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 ELECTRICAL-MECHANICAL ACCIDENTS

5. 56.12016 Working on electrically-powered equipment. Deenergized, locked and tagged - removed only by who installed 56.12017 Work on power circuits. Deenergized, locked and tagged - removed only by who installed - hot work only by equipped and qualified 56.14105 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 energizedstinger 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)

28. THE END