Safety Engineering: Achieving Hazard Control and Stored Energy Awareness

1. Awareness of Stored Energy MTU Mine Safety & Health

2. Stored Energy • Hazard Control • Safety Engineering - Technology • Identification of Hazards • Evaluation of Hazards • Control of Hazards • Safety Management – Administrative • Safety Program Elements Alive & Well • Establishment of Policies • Development of Procedures

3. Stored Energy • Hazard Control Priority • Eliminate Hazard • Not Always Possible • Reduce Hazard • Modify Design • Redundancy – Requiring Multiple Point Failure • Safety Devices • Guards, Interlocks, Fences • Yet may be circumvented by operators • Warning Devices • Do Not Eliminate Hazard, Nor Do They Provide Protection • Requires Human Perception and a Willingness to Participate • Procedures • Require Learning, Understanding, Practice • Design of Procedures Critical and must Reflect Human Characteristics, Capabilities, and Limitations • Vary Greatly Between Individuals

4. Stored Energy • Hazard Identification • Energy Analysis • Injury cannot occur without the presence of some form or Exchange of Energy • Thus: Hazard Identification – Energy Identification • i.e. An unanticipated, undesirable release or exchange of energy in a system may cause an accident and subsequent operator injury and/or system damage • Energy Management • Type of energy • Amount of energy • Release of energy • Rate at which energy is released • To a level tolerable by humans

5. Stored Energy Lockout Programs must address Stored Energy • Awareness of how Energy is Transferred and Potentially Stored is essential • An Assessment of the Systems involved is required • Simply locking out a particular machine is not enough • All stored energy must be Relieved • Verify that there is No Potential for Re-Accumulation • Assessment of related equipment • A clear policy and written procedures and instructions are essential and address: • Scope • Purpose • Authorization • Rules • Techniques

6. Stored Energy 7 – Step Lockout Process • Prepare to shut down equipment • Shut down equipment • Isolate equipment from ENERGY SOURCES (???) • Apply lockout devices • Verify isolation • Control STORED ENERGY • Prepare for Startup (After work is done)

7. Stored Energy • SLAM RISKS (Things Change !) • Stop – and consider the work involved • Look – for and identify the hazards • Analyze – what needs to be done • Manage – safety by developing & implementing controls • Remember – to look for changes • Identify – all potential risks • Share –what you find, include others impacted by job & risk • Know – what others on your jobsite are doing • Safety – is everyone’s job!

8. Stored Energy • Hazard Identification - A Primary Concern • Personnel must be aware of Hazardous Energy in its many different forms • Systems, whether Energized or Not, can produce Hazardous Energy • Unexpected and unrestricted Release of Hazardous Energy can occur if: • All energy sources are not Identified • Provisions are not made for Safe Work Practices with energy present • Stored energy associated with Deactivated Energy Source has not been Dissipated • Reduced to levels that are tolerable by humans

9. Stored Energy • Case A • Explosives (Chemical Energy) • Individuals realize the Potential • Government Regulations (CFR) • Manufacture • Storage • Transportation • Use • Electric Blasting • Nonelectric Blasting • Extraneous Electricity • Equipment / Tools • General Requirements • Safe Operating Procedures (SOP’S) • Written document setting out the procedures that must be followed

10. Stored Energy • Yet - - - Case B - - - Case C - - - etc. • Energy • Types of Energy • Potential Energy – Stationary (Stored?) • Kinetic Energy – Moving (Contains?) • Forms of Energy • Mechanical • Electrical • Chemical • Nuclear • Thermal • Radiant • Acoustic • Other

11. Stored Energy • Examples of Potential Energy • Gravitational • Supporting structures • Suspended loads • Mechanical • Cable in tension • Spring • Pressurized Fluids • Hydraulic • Pneumatic • Steam • Electrical • Capacitors • Electromagnetic • Chemical • Fuels • Batteries • Nuclear • Magnetic field • Other

12. Stored Energy • Examples of Kinetic Energy • Gravitational • Falling object • Radiant • Mechanical • Flying object • Impact of a moving against a stationary object • Impact of two objects moving toward each other • By virtue of its Motion • Inertia – A measure of a bodies resistance to change in motion • A Stable object resistance to being moved • A Moving object resistance to being stopped

13. Stored Energy • “Stored” Energy • With regard to physics Stored only represents Potential • Yet all six of the major energy classifications can be “Stored” in some form of this general energy classification except Radiant or electromagnetic which purely transitional • Mechanical can be stored as potential or kinetic – flywheel • Electrical can be stored as either inductive or electrostatic field • Chemical and Nuclear are pure forms of stored energy • Thermal can be stored as either • Sensible heat – simply increase in temperature • Latent heat – involves a phase change - - - solid to liquid

14. Stored Energy Assessment of Stored Energy • Identify energy sources & potential means for storage of energy • De-energize equipment by isolating or blocking energy sources • Lock-out the equipment’s energy isolating device(s) • Isolate or Relieve all stored energy and verify that energy has been dissipated • Verify that there is no potential for re-accumulation • Critique the situation

15. Stored Energy • Gravitational Energy • By virtue of its Position • Supporting structures • An accident waiting to happen

16. Stored Energy • Gravitational Energy • Loss of structural integrity as a result of Corrosion • Unauthorized Modification of Structure • Impact to a Member results in Weakening of Structure Oops – Bad Day

17. Stored Energy • Gravitational • Fall of roof or back • Scaling, Bolting • Look for deterioration in ground support • Use of RF remote controls • Redundancy in controls “Proximity”

18. Stored Energy • Fall of Roof or Back Fatalities 2006 • 01/10/06, 44yr, 15yr exp –Rock fell from roof • 02/16/06, 33yr, 7yr exp –Struck by draw rock • 03/29/06, 57yr, 23yr exp –Rock fell from roof • 04/20/06, 28yr, 2yr exp –Rock fell from roof

19. Stored Energy • Gravitational Energy • Cables In Tension • Never stand below suspended load • Use of tag lines • Understanding Loads • Imposed on equipment • Applied to the cable • Capacity of equipment • Design • Testing – Plate/Johnny’s Prevention of Rigger Mortis

20. Stored Energy • Slip / Fall of Individual Fatalities • 05/22/06, 42yr, 15yr exp –Fell 17ft from forks of forklift • 06/28/06, 49yr, 20yr exp –Fell through roof hatch cover • 08/17/06, 37yr, 15yr exp –Fell 28ft to concrete floor

21. Stored Energy • Mechanical / Gravitational Energy • Conveyors • Belt • Flighted • Bucket Elevators • Belt • Chain link • Cable Assemblies • Aerial Tramways • Slings & Bridles • Cable & Chokers Systems • Power Transmission • Electric Brake system • Backstops or Holdbacks

22. Stored Energy • Mechanical / Gravitational Energy • Power Transmission • Electric drives • Drive Belts • Reducers • Backstops or Holdback • Not always beneficial

23. Stored Energy • Mechanical / Gravitational Energy • Potential Energy Size reduction equipment • Involve large heavy components • Crushing • Cleared Ore from unit before servicing • Grinding • Potential Energy resulting from unbalanced charge • Classification • Position of counterweight • Springs, etc

24. Stored Energy • Mechanical Energy • Cables In Tension • Danger Zones • Potential failure of cable - Loss of foot • Inertia of Conveyor & Coal

25. Stored Energy • Powered Haulage Fatalities 2006 • 04/04/06, 23yr, 1m exp –Entangled in belt & tail pulley • 05/03/06, 19yr, 4w exp –Entangled in belt & return idler • 05/23/06, 44yr, 11yr exp–Crushed between loader/conveyor

26. Stored Energy • Machinery Fatalities 2006 • 01/12/06, 39yr, 12yr exp -pinned by rear frame of loader • 02/13/06, 25yr, 2 1/2yr exp -Struck by suspended load

27. Stored Energy • Gravitational Energy • Mobile Equipment • Pre-Operational checks • Inspect Dumping locations prior to dumping first load

28. Stored Energy • Gravitational Energy • Mobile Equipment • Grade Level / Inclined surface • Stability of surface • Recent weather • Seat Belts !!!

29. Stored Energy • Mobile Equipment Powered Haulage Fatalities 2006 • 01\27\06, 60yr, 10yr exp –Dozer traveled over 50ft wall • 04/11/06, 22yr, 9m exp –Struck by skid steer backing up • 04/22/06, 53yr, 33yr exp –Run over by front-end loader • 06\12\06, 39yr, 14m exp –Boom fell & pinned against frame • 07/15/06, 61yr, 40yr exp–Backed truck into water filled pit • 08/29/06, 61yr, 31yr exp –Struck by front-end loader

30. Stored Energy • Fall / Sliding Material Fatalities 2006 • 04\21\06, 35yr, 11m exp –Pinned by loose off highwall • 05\26\06, 58yr, 12yr exp –Bank collapsed & slid into water