Meikle Backfill Materials Supply System Operator Manual

MMeeiikkllee BBaacckkffiillll MMaatteerriiaallss SSuuppppllyy SSyysstteemm OOppeerraattoorr TTrraaiinniinngg MMaannuuaall

Table of Contents

1. Forward ................................................................................................................................................................. 3 2. Important Safety Information................................................................................................................................. 3 3. Safety Alerts........................................................................................................................................................... 4 4. Safety Signs and Labels........................................................................................................................................... 4 5. Definitions ............................................................................................................................................................. 5 6. Basic Systen Overview............................................................................................................................................ 7 7.Workplace and Equipment Examinations ................................................................................................................ 8

7.1 925 Pre-Shift Work Area Inspection.............................................................................................................. 8 7.2 925 Aggregate Bin Bulkhead Number One Inspection .................................................................................. 9 7.3 925 Multiclone Inspection and Daily Maintenance ..................................................................................... 11 7.4 925 Aggregate Bin Bulkhead Number Two Inspection ................................................................................ 15 7.5 860 Cement and Fly Ash Hopper Inspection ............................................................................................... 16 7.6 Vent Shaft MCC Inspection......................................................................................................................... 17 7.7 Vent Shaft MCC Control Panel identification and operations ...................................................................... 18 7.8 Meikle Backfill Materials Supply System Faults .......................................................................................... 22 7.9 Meikle Backfill Aggregate Supply inspection .............................................................................................. 23

8. Meikle Backfill Aggregate Supply operation ......................................................................................................... 26 9. Meikle Backfill Aggregate Supply post-operation inspection................................................................................. 30 10. CEMA Conveyor Safety and Labels...................................................................................................................... 31 11. LOTO FAB ........................................................................................................................................................... 33 10. NIOSH Control of Hazardous Energy Safety......................................................................................................... 34 11. Neutralite Skin Care Safety................................................................................................................................. 49 12. MSDS's ............................................................................................................................................................... 52 13. Multiclone Installation and Operation ................................................................................................................ 61 14. Screw Conveyor Corporation Documentation..................................................................................................... 76 15. Engineering and Maintenance............................................................................................................................ 93

Last Modified Wednesday, 16 March 2011 UG Division Training Department 2 | P a g e

Forward

Purpose

The intent of this training manual is to ensure the safety of personnel working in the role of Meikle Backfill Materials Supply System Operator, control or eliminate hazardous conditions associated with the Meikle Backfill Materials Supply System, and to prevent or control environmental deviations which violate Barrick Goldstrike's EPA Clean Air Act Title V Permit.

Scope

This training manual is specific to the Underground Division and is designed to comply with 30 CFR Part 48 training requirements including the Health and Safety aspects of the equipment and/or procedures. The training procedures outlined apply to all personnel, both company and contract, working in the role of Meikle Backfill Materials Supply Operator.

This training procedure is designed to increase production through safe, consistent, systematic, and controlled training methods in accordance with Barrick Goldstrike Underground Division's Policies and Procedures, State and Federal Regulations. All training is to be conducted by a "Qualified" field trainer as outlined by the Barrick Goldstrike Underground Division Training Department in collusion with the Underground Division Management Group. All training will be verified and audited by the Underground Division Training Department.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written by the Barrick Goldstrike Underground Division Training department. The underground training department did not manufacture nor can this group be considered experts in the manufacture of the components of this equipment. Technical information has been acquired from the Manufacturers of components, where available, and from the Barrick Goldstrike Underground Division Fixed Maintenance, Electrical, and Engineering Departments. The specifications, programming, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to, and/or the operations of, this equipment. The Barrick Goldstrike Fixed Maintenance, Electrical, and Engineering Departments should be contacted for the most current information available.

The safety of the personnel operating this equipment is the priority of this training procedure therefore any proposed change to the equipment in this training or proposed change to the training procedure shall be subject to the Barrick Management of Change (MOC) and Risk Assessment processes.

Important Safety Information

Most accidents that involve equipment operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this equipment can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair

on this equipment, until you have read and understood the operation, lubrication, maintenance, and repair information.


Safety precautions and warnings are provided in this manual and on the equipment. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

NEVER BYPASS SAFETY DEVICES OR SAFETY EQUIPMENT. Failure to follow these instructions could result in serious or fatal injuries to personnel, environmental deviation, or damage to property. See

"Standards of Conduct" Policy

30 CFR 57.7002 Equipment defects.

Equipment defects affecting safety shall be corrected before the equipment is used.

Safety Alerts

Symbol

This Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

The Safety Alert Symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message

Why is SAFETY important to you?

ACCIDENTS DISABLE AND KILL

ACCIDENTS COST

ACCIDENTS CAN BE AVOIDED

Signal Words

Signal words are distinctive words that will be found on the upper panel of safety signs on this machine and other equipment on the worksite. These words are intended to alert the viewer to the existence and relative degree of a hazard.

This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This signal word indicates a potentially hazardous situation which. if not avoided, could result in death or serious injury.

This signal word indicates a potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury.

MSHA Compliance

Information containing this safety alert is taken directly from the code of federal regulations for MSHA compliance.


Safety Signs and Labels

There are several specific safety signs on this equipment. Please become familiarized with all safety signs. Make sure that all of the safety signs are legible. Clean the safety signs or replace the safety signs if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the safety signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety sign. Loose adhesive will allow the safety sign to fall. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.

Bilingual Lock out labels Lock out and/or tag out all energy sources to conveyor system and loading system before performing any work on conveyor or conveyor accessories. Failure to do so could result in severe injury or death.

Bilingual Pinch Point labels

Special attention, blocking, or guarding required when working in or near pinch points.

Danger Open Hole Signs

Fall protection required when working around open holes.

Keep Out Signs

Communication or special instructions

Danger Do Not Enter Signs

Authorized personnel only

Falling Rock Unauthorized Entry Prohibited Signs

Falling materials hazards Superintendants authorization required before entry NO EXCEPTIONS

Open Hole Signs

Fall protection required when working around open holes.


Authorized Personnel Only Signs

Authorization required before entry.

Active Backfill Transfer Raise

Falling material hazards

Definitions Admixture - The chemicals used to aid the properties of concrete or cement.

Aggregate - An aggregate is a collection of items that are gathered together to form a total quantity.

Aggregate (composite), in materials science, a component of a composite material used to resist compressive stress.

Construction aggregate, materials used in construction, including sand, gravel, crushed stone, slag, or recycled crushed concrete.

Berm - A pile or mound of material capable of restraining a vehicle.

Bulkhead - An upright wall used to separate/seal portions of the mine and/or used to direct the flow of ventilation underground.

Belt Conveyor - A looped belt on which coal or other materials can be carried and which is generally constructed of flame-resistant material or of reinforced rubber or rubber-like substance.

Cement - In the most general sense of the word, cement is a binder, a substance that sets and hardens independently, and can bind other materials together. Concrete should not be confused with cement, because the term cement refers to the material used to bind the aggregate materials of concrete. Concrete is a combination of a cement and aggregate.

Cement is made by heating limestone (calcium carbonate), with small quantities of other materials (such as clay) to 1450 C in a kiln, in a process known as calcination, whereby a molecule of carbon dioxide is liberated from the calcium carbonate to form calcium oxide, or quicklime, which is then blended with the other materials that have been included in the mix. The resulting hard substance, called 'clinker', is then ground with a small amount of gypsum into a powder to make 'Ordinary Portland Cement', the most commonly used type of cement (often referred to as OPC).

Cemented Rockfill - Cemented rockfill, CRF, is comprised of sized aggregate mixed with various types and amounts of binder materials. This type of fill with closely controlled specifications is employed for subsequent pillar recovery and improved ground support.

Competent Person - A "competent person," according to 56/57.2, is "a person having abilities and experience that fully qualify him to perform the duty to which he is assigned."

Magnehelic Gauge - A magnehelic pressure gauge is a device, similar to a manometer, used to measure positive, negative and differential pressures. These gauges are often used in the HVAC industry to measure pressure drop across air filters to determine when it is time for them to be changed.


Multiclone Dust Collector - Designed to handle heavy dust loads, a dust collector system consists of a blower, dust filter, a filter-cleaning system, and a dust receptacle or dust removal system. It is distinguished from air cleaners which use disposable filters to remove dust.

Fault - May refer to:

Fault (technology), an abnormal condition or defect at the component, equipment, or sub-system level which may lead to a failure

Fault (power engineering), an unintended electrical connection, a "short circuit", may be an asymmetric or a symmetric fault

Fault (computing), a type of interrupt in software or operating systems

Fly Ash - Referred to as a pozzolan

Definition: POZZOLAN, n., a siliceous or siliceous and aluminous material which in itself possesses little or no cementitious

value but which will, in finely divided form and in the presence of moisture, chemically react with calcium hydroxide to form compounds possessing cementitious properties

Fly ash is a high temperature by-product of coal combustion, collected from the combustion gasses. Two Types: Type C-Cementitious & Type F-Filler

Portland cement - Portland cement is a basic ingredient of concrete, mortar and most non-specialty grout. The most common use for Portland cement is in the production of concrete. Concrete is a composite material consisting of aggregate (gravel and sand), cement, and water. As a construction material, concrete can be cast in almost any shape desired, and once hardened, can become a structural (load bearing) element. Portland cement may be grey or white.

Bags of cement routinely have health and safety warnings printed on them because not only is cement highly alkaline, but the setting process is exothermic. As a result, wet cement is strongly caustic and can easily cause severe skin burns if not promptly washed off with water. Similarly, dry cement powder in contact with mucous membranes can cause severe eye or respiratory irritation. Cement users should wear protective clothing.

Safety Device - A device designed to prevent injury or accidents.

Working Place (Workplace) - The phrase "working place" is defined in 30 CFR 56/57.2 as: "any place in or about a mine where work is being performed." As used in the standard, the phrase applies to those locations at a mine site where persons work in the mining or milling processes.

Basic System Overview

The Meikle Backfill Material Supply System contains several components, some of the system components are on surface and the others are underground.

The surface components include the Cement and Fly Ash silos next to the Meikle Ventilation Shaft, the Aggregate Delivery Conveyor and Hopper, as well as the Vent Shaft Motor Control Center (MCC).

The underground components are made up of the Meikle Aggregate Bin, the 925 Multiclone Dust Collector and the 860 Cement and Fly Ash Hoppers.

All of these components feed materials to the Meikle 1075 Backfill Plant. When the Backfill Operator requests a batch of Cemented Rockfill through the computer activated PLC the Aggregate flows from the Aggregate Bin through a gate onto


the underground Aggregate Belt Conveyor into the mixer. Then the aggregate is mixed with Cement, Fly Ash, Water, and Admixtures to create a pre-determined amount of Cemented Rockfill. As the materials are used and more are needed the Backfill Plant Operator communicates with the Surface operator through lights that are positioned on the surface Aggregate Hopper, on the phone, through dispatch, or on the radio.

Cement and Fly Ash are delivered to the Silos which are plumbed to the 860 level Hoppers then to the 1075. Aggregate is delivered through the surface Aggregate Hopper, over the Belt Conveyor and down a 24 pipe into the top of the Aggregate bin. Admixtures are stored and delivered at the 1075 level and the water is plumbed in from the underground utilities.

Before starting work all workplaces and equipment must be visually inspected to ensure the safety of personnel, control or eliminate hazardous conditions associated with the Meikle Backfill Materials Supply System, to prevent or control environmental deviations which violate Barrick Goldstrike's EPA Clean Air Act Title V Permit, to prevent damage to property, and to increase production by preventing/minimizing downtime.

Workplace and Equipment Examinations

30 CFR 57.18002 Examination of Working Places

Examination of working places, provide

a. A competent person designated by the operator shall examine each working place at least once each shift for conditions which may adversely affect safety or health. The operator shall promptly initiate appropriate action to correct such conditions.

b. A record that such examinations were conducted shall be kept by the operator for a period of one year, and shall be made available for review by the Secretary or his authorized representative.

c. In addition, conditions that may present an imminent danger which are noted by the person conducting the examination shall be brought to the immediate attention of the operator who shall withdraw all persons from the area affected (except persons referred to in section 104(c) of the Federal Mine Safety and Health Act of 1977) until the danger is abated.

All personnel including employees, contractors, and vendors are required to complete a workplace exam and a 5 point safety system record of examination card. All hazardous conditions are to be noted on the card as well as the corrective actions taken. The 5 point safety system record of examination must also include: (1) the date the examination was made; (2) the examiner's name; and (3) the working places examined.

925 pre-shift work area inspection 30 CFR 57.18002

Barrick Goldstrike Underground Division 5-Point Safety System Policy #15-003:

Conduct and document a thorough inspection. The inspection should start from the time you walk to the collar. Take care of any deficiencies found during the inspection immediately or barricade the area off until the deficiencies are corrected. Make sure water, grease, oil, snow, and ice, which may cause a slip and fall hazard, have been cleaned up.

Inspect the 925 level accesses to the Multiclone work area for hazards to personnel before beginning equipment inspections.

Check the condition of scaling bar/s and scale down as required. Inspect for unstable ground conditions from station to equipment location. Inspect for cracks in the shotcrete. Inspect for areas that require rehab, note


deficiencies on 5 a point inspection card, and report the area to the shift supervisor or lead miner, barricade the area to be rehabbed if necessary. Policy # 1-005, 30 CFR 57.3200 Correction of hazardous conditions, and 30 CFR 57.3360 Ground support use.

Remove all bent or broken scaling bars and modified tools from the area and take to the proper disposal area 30 CFR 57.14205.

Inspect for misrounds in areas of active mining. A misround is a blast area which did not initiate correctly for a number of reasons. If a misround is found the area is to be barricaded or guarded from all entrances. Contact the shift supervisor and powder crew to report the work area immediately. Always look for misfires/misholes and live explosives in all work areas. Blasting is an essential step in the mining process and misfires/misholes have been found long after the work area was developed. A misfire is defined as: "misfire (mishole)" means a charge or part of a charge which, on initiation, failed to completely detonate or function. If a mishole/misfire is found guard or barricade the area then contact the shift supervisor and powder crew to report the area. Only personnel who have been granted an "Employee Possessor Letter of Clearance" by the BATFE, and who are properly trained, may handle explosives.

Wet down the ribs and roads in accesses if required. Take care not to wet electrical components, sweep over, or hold water directly on power cables.

Inspect for low hanging, damaged, or leaking utilities. Inspect lighting and power cables, report damage or repairs to the electrical department. Inspect and repair barricades, signage, and reflective demarcation poles. Policy # 17-001, and 30 CFR 57.20011

Barricades and warning signs Inspect vent bag and vent tube for damage. Never enter inactive areas that are barricaded and signed "Inactive

Work Area" or "Unventilated Area". Re-entry into inactive work areas is covered in Policy #1-002 Entering Abandoned, Inactive Work Areas.

Inspect the fire extinguisher and replace if necessary 30 CFR 57.4201. Demonstrate knowledge of fire extinguisher usage, and equipment fire procedures.

Demonstrate knowledge of the locations of the nearest escape ways to the level above and the level below as well as the nearest refuge chamber or shaft stations, and evacuation procedures.


925 Aggregate Bin Bulkhead Number One pre-shift work area inspection

925 Aggregate Bin Bulkhead Door Number One

30 CFR 57.16002 NEVER BYPASS SAFETY DEVICES OR SAFETY EQUIPMENT. Failure to follow these instructions could

result in serious or fatal injuries to personnel, environmental deviation, or damage to property. See "Standards of Conduct" Policy

A formal risk assessment has been completed on this equipment, it has been determined that at no time shall any person gain access to the Meikle Aggregate Bin without the authorisation of a Superintendent, no exceptions. Guidelines for entry into the Meikle Aggregate Bin will be addressed in a separate procedure and strictly enforced. It is vital that a thorough inspection of the Meikle Aggregate Bin bulkheads be conducted each shift.

Due to the possibility of extreme weight being applied to this door, the open hole inside of the door, the possibility of falling material and the amount of open ground in this work area this inspection is considered a critical task when operating the Meikle Backfill Materials Supply System. Personnel shall never open inspection doors, or attempt to open bulkheads until all safety procedures have been put in place. If at any time it is suspected that personnel have attempted to gain unauthorized access to the Aggregate Bin report the attempt to management immediately.

The Agg Bin doors have been engineered to withstand extreme weights and stresses, all structures around the agg bin have been considered including ground conditions, and ground support. The safety of personnel is the most important consideration when inspecting this work area, therefore;

Inspect and repair all signage. All signs must be visible and legible. Inspect the "Engineered Bulkhead Door" for signs of stress, failure, and/or bowing. Inspect the hinges for signs of fatigue, stress, or failure. Inspect structure bolts where visible for signs of loosening. Inspect the access panels where visible for signs of tampering.


30 CFR 57.16002 Bins, hoppers, silos, tanks, and surge piles.

(a) Bins, hoppers, silos, tanks, and surge piles, where loose unconsolidated materials are stored, handled or transferred shall be

(a)(1) Equipped with mechanical devices or other effective means of handling materials so that during normal operations persons are not required to enter or work where they are exposed to entrapment by the caving or sliding of materials; and

(a)(2) Equipped with supply and discharge operating controls. The controls shall be located so that spills or overruns will not endanger persons.

(b) Where persons are required to move around or over any facility listed in this standard, suitable walkways or passageways shall be provided.

(c) Where persons are required to enter any facility listed in this standard for maintenance or inspection purposes, ladders, platforms, or staging shall be provided. No person shall enter the facility until the supply and discharge of materials have ceased and the supply and discharge equipment is locked out. Persons entering the facility shall wear a safety belt or harness equipped with a lifeline suitably fastened. A second person, similarly equipped, shall be stationed near where the lifeline is fastened and shall constantly adjust it or keep it tight as needed, with minimum slack.

30 CFR 57.20011 Barricades and warning signs.

Areas where health or safety hazards exist that are not immediately obvious to employees shall be barricaded, or warning signs shall be posted at all approaches. Warning signs shall be readily visible, legible, and display the nature of the hazard and any protective action required.

Notify the shift Supervisor immediately if any deficiencies are found in this inspection.


925 Multiclone Inspection and Daily Maintenance

925 Multiclone Dust Collector

THIS EQUIPMENT STARTS AUTOMATICALLY!

This system has been designed to start the multiclone when the surface aggregate delivery conveyor starts.

Inspect the Multiclone for loose or missing structure bolts. Inspect the Multiclone Fan, ensure all guards and covers are in place and properly secured. Inspect the Screw Conveyor. Screw conveyors shall not be operated unless the conveyor housing completely

encloses the moving elements and all power transmission guards are in place.

Screw Conveyor Power Transmission

Screw Conveyor Shaft

Pinch Valve


Lockout Tagout required before removing gearbox guards or conveyor housing. See Lockout Tagout Policy #11015.

Each shift the bearing at the discharge end of the screw conveyor, and the bearings for the fan require two pumps of grease.

Fan Motor and Fan Bearing Grease Screw Conveyor Shaft Bearing Inspect the filter inspection/replacement doors; ensure all door tensioners are tight. Lockout Tagout required

before opening filter inspection/replacement doors. See Lockout Tagout Policy #11-015.

Multiclone After Filter Replacement Doors Lockout Tagout Required Before Replacing Filters

There are two switches that assist in the operation of the multiclone. One switch operates the multiclone fan and the other operates the screw conveyor. Both switches have a "Hand" and "Auto" setting and need to be in the "Auto" position to work properly with the program. If one or both are left in the "Hand" position the system will receive a fault and will not start.

Hand Position Switches to the left

Auto Position Switches to the right


reads 1 of differe the filters are n

ifferential pressure gged and need to b ma n enance can on y e accomp s e a er proper oc ou agou proce ures ave een o owe . oc Tagout of this system starts at the surface.

Lockout Tagout for working on the Multiclone starts at the surface to ensure that the system cannot start automatically while personnel are working. The procedure at the Multiclone is to turn the screw conveyor switch to the off position then the fan switch to the off position, close the breaker panel and place personal lock or lock out tree to the door handle.

Housekeeping and safe access to all work areas are always a concern for employees as well as machinery. Operators must maintain their work areas to ensure the safety of all personnel who might be working at the Multiclone.

The filtration system is monitored in two ways; 1. There is a photohelic that has been installed on the after filter that is monitored by Cimplicity. The second is a magnehelic which is monitored by operations and fixed maintenance. If the magnehelic ntial pressure then ew. However if the magnehelic reads 3.5 to 4 of d the filters are plu e changed. Filter

i t l b li h d ft L k t T t d h b f ll d L kout

Turn Off Dust Collector

Turn Off Screw Conveyor

Photohelic Static Pressure Gauge

Lockout Tagout Multiclone Dust Collector when performing work. LOTO begins at Vent Shaft MCC

Magnehelic Static Pressure Gauge

NOTE: See manufacturers documentation for recommended operations and maintenance instructions

30 CFR 56.20003 Housekeeping.

At all mining operations

(a) Workplaces, passageways, storerooms, and service rooms shall be kept clean and orderly;

(b) The floor of every workplace shall be maintained in a clean and, so far as possible, dry condition. Where wet processes are used, drainage shall be maintained, and false floors, platforms, mats, or other dry standing places shall be provided where practicable; and


(c) Every floor, working place, and passageway shall be kept free from protruding nails, splinters, holes, or loose boards, as practicable.

found in later sections of this manual.

Note:

More safety and maintenance information for the Multiclone Dust Collector and Screw Conveyor can be

925 Aggregate Bin Bulkhead Number Two pre-shift work area inspection

925 Aggregate Bin Bulkhead Number Two

30 CFR 57.16002 NEVER BYPASS SAFETY DEVICES OR SAFETY EQUIPMENT. Failure to follow these instructions could

result in serious or fatal injuries to personnel, environmental deviation, or damage to property. See "Standards of Conduct" Policy

A formal risk assessment has been completed on this equipment, it has been determined that at no time shall any person gain access to the Meikle Aggregate Bin without the authorisation of a Superintendent, no exceptions. Guidelines for entry into the Meikle Aggregate Bin will be addressed in a separate procedure and strictly enforced. It is vital that a thorough inspection of the Meikle Aggregate Bin bulkheads be conducted each shift.


Although this Agg Bin door is not expected to accumulate the same amount of weight, nor is it anticipated to attain the same amount of stress as Agg Bin Bulkhead Door number one, it is still necessary to complete a thorough inspection of this structure and report signs of failures to management. A failure of the Agg Bin Doors, on either side, would expose personnel to serious or fatal injuries.

860 Cement and Fly Ash Hopper Inspection and Daily Maintenance

Although the 860 level components play a vital role in the daily operations of delivering cement and fly ash material to the Meikle Backfill Plant, this part of the system is automated and management has determined that the operator does not need to be trained for these components.

Should a fault occur at the 860 level components, the operator should contact the fixed maintenance and/or electrical department to inspect the components to determine the reason for the occurrence before clearing the fault. Personnel who are not trained cannot be considered Competent, and therefore risk serious or fatal injuries if these instructions are not followed.

Cement and Fly Ash Silo inspection

Meikle Backfill Material Supply System Cement and Fly Ash Silos

Inspect the cement and fly ash silos for damage, housekeeping, slip, trip and fall hazards. Monitor pop off valves, fittings, and hoses for unwanted emissions which violate the EPA Clean Air Act Title V

permit and report violations to the shift Supervisor or Environmental group.

NOTE: Contact Fixed Maintenance for repair or maintenance needs


Vent Shaft MCC Inspection

Meikle Ventilation Shaft Motor Control Center (MCC) Entrance

Motor Control Centers (MCCs) can be dangerous to personnel as well as property. Report all

unsafe conditions to the Electrical Department immediately and barricade the MCC if necessary. DO NOT

attempt to operate the Meikle Backfill Delivery System if unsafe electrical conditions exist.

The Vent Shaft MCC communicates with the rest of the Meikle Backfill Materials Supply System. This is where the Lockout Tagout process for this system begins and ends.

Inside of this room is where the system faults are cleared and the main system start/stop switches are located. Before resetting any fault it is recommended that the operator find the reason for the fault, log the fault (time, date, type, and reason), then report it to the supervisor at the end of shift unless the fault creates a hazard to personnel. If the fault creates a hazard to personnel the system is to be Locked Out and Tagged Out, barricaded if necessary and reported immediately. Inspect entryways and walkways to ensure safe access, 30 CFR 56.11001, and egress out of the MCC and Vent

Shaft Headframe. Inspect handrails, steps, and safety chains or swing gates. Report unsafe conditions to fixed maintenance. Inspect fire extinguisher inside of the MCC 30 CFR 57.4201. Demonstrate knowledge of fire extinguisher usage,

and electrical equipment fire procedures for surface. Inspect air lines, water lines, power cables, lighting, and housekeeping 30 CFR 57.20003. Inspect electrical outlets for damaged or missing covers. Inspect control boxes, cabling, and grommets. Report damaged components, exposed wires, and protective

jackets that are damaged or pulled from the panel grommets to the electrical department. Inspect labelling on control panels and disconnects, report deficiencies to the electrical department. Inspect communications for damage and test for communications with the Meikle Backfill Plant Operator and

Meikle Dispatch Operator.


Vent Shaft MCC Control Panel Identification and Operations

Although this system has been designed for ease of use by the operator, it is still necessary to understand the communications between the control panel and the rest of the system in order to prevent or minimise the Meikle Backfill Plant downtime and clear faults or trace unplanned events which may occur with the system. The following is a list of buttons and associated lights that will help determine what sequence needs to be followed if an unplanned fault or event does occur.

On occasions where faults, unplanned events, or system failures occur, which cannot be cleared by the Meikle Backfill Plant Operator or the Meikle Backfill Materials Supply Operator, the system shall be powered off, locked out, and tagged out. Contact the electrical group to report the system failure. Do not continue to run the system with system failures without authorisation from a Superintendent.

NEVER BYPASS SAFETY DEVICES OR SAFETY EQUIPMENT. Failure to follow these instructions could result in serious or fatal injuries to personnel, environmental deviation, or damage to

property. See "Standards of Conduct" Policy

Left Control Panel controls the Agg Delivery System

Right Control Panel controls the Cement and Fly Ash

Delivery System


Lights and buttons on the control panel - left door

1. Power On/Press to Test - The light will be on if there is 120V power turned on in the cabinet. The button will turn on all the lights to check bulbs.

Vent Shaft MCC Left Panel Control Door

8. Conveyor Belt Alignment Switch - The light will flash when the alignment switch is tripped on either side. 9. Conveyor Pull Cord Switch - The light will flash when the conveyor belt pull cord is tripped on either side. 10. Conveyor Motion Failure Sensor - The light will flash when the motion failure switch is tripped. This will happen

when the switch doesn't see the tail pulley moving when it is given a run command after approx. 25 seconds. 11. Aggregate Hopper Plugged - The light will flash when the hopper plugged switch is tripped.

2. System Failure/Reset - The light will blink when there is a system fault. The button will reset a latched fault.

3. 1090 Level Emergency Stop - The light will blink when the 1090 level has the E Stop pressed.

4. 925 Dust Collection Failure - The light will flash if the 925 dust collector fails to start.

5. 925 Dust Collector Run Status - The light will be on when the 925 dust collector is running.

6. 925 Dust Collector Auto - The light will be on when the 925 dust collector is in auto.

7. Conveyor Auto Mode - The light will be on solid when the conveyor is in auto. The light will flash when the conveyor is in manual.


13. Aggregate Conveyor Stop/Ready - The light will come on solid when the conveyor is not running but is ready to run. The button will stop the conveyor belt if it is running. There is also a remote stop button on the electrical panel by the conveyor belt.

14. Transfer Chute Plugged - The light will flash when the pipe is plugged.

Vent Shaft MCC Left Panel 15. 860/1090 Level Ready - The light will come on solid when the 860 Control Door

Level is ready.

12. Aggregate Run/Start - The light will come on solid when the conveyor is running. The button will start the conveyor belt. There is a few second delay from when the button is pressed and the belt actually starts the warning horn will be sounding during this duration. There is also a remote start button on the electrical panel by the conveyor belt.

Just to clarify/explain the Meikle Backfill Plugged Pipe/System Plugged fault (red blinking plugged chute/pipe, green blinking 860/1090, blinking red system fault indicator lights on the surface panel)If the system goes down on plugged pipe there is a 30 minute timer which will lock out the system from being reset. Once the 30 minutes have passed, the reset button may be pressed which will turn off the plugged pipe fault indicator light and turn the 860/1090 indicator light to solid green, the system fault indicator light will still be blinking red. Pressing the reset button again will then reset the system fault. This should be the only fault which requires two resets to get the system going again.

16. South Pipe Running - The light will come on solid when the pipe sensor at the bottom of the pipe at the 925 is detecting material. The light will blink when the conveyor is running but the sensors at the 925 don't detect material within a specified amount of time.


Lights and buttons on the control panel - right door

Vent Shaft MCC Right Side Control Panel Door

1. Cement Level Alarm Low - The light will flash when the cement level is below 20% or when the switch is tripped.

2. Cement Conveyor Auto - The light will come on solid when the surface cement screw conveyor is selected in auto. The light will flash when the surface cement screw conveyor is selected in manual.

3. Aeration Blower Auto - The light will come on solid when the aeration blower is selected in auto. The light will flash when the aeration blower is selected in manual.

4. Fly Ash Screw Conveyor Auto - The light will come on solid when the surface fly ash screw conveyor is selected in auto. The light will flash when the surface fly ash screw conveyor is selected in manual.

5. Fly Ash Level Alarm Low - The light will flash when the fly ash level is below 20% or when the switch is tripped.

6. Surface Cement Diverter Valve Open - The light will come on solid when the cement side of the diverter valve is opened.

7. Cement Screw Conveyor Start/Run 8. Aeration Blower Start/Run 9. Fly Ash Screw Conveyor Start/Run 10. Surface Fly Ash Diverter Valve Open - The light will come on solid

when the fly ash side of the diverter valve is opened.

11. 860 Cement Hopper Fail to Refill - The light will flash when the 860 cement hopper doesn't refill in a specified amount of time.

12. Cement Screw Conveyor Stop/Ready 13. Aeration Blower Stop/Ready 14. Fly Ash Conveyor Stop/Ready 15. 860 Fly Ash Hopper Fail to Refill - The light will flash when the 860 fly ash hopper doesn't refill in a specified

amount of time.


16. 860 Level Cement Diverter Valve Open 17. 860 Level Request For Cement 18. 860 Level Request For Fly Ash 19. 860 Level Fly Ash Diverter Valve Open

20. Reset 21. 860 Dust Collector Failure Reset 22. 860 Dust Collector Run Status 23. 860 Dust Collector Auto Status

24. Low Plant Air Pressure 25. 860 Dryer Run

MCC Bucket Labelled Aggregate Conveyor VFD

Before performing maintenance on the Backfill Delivery System or working in the

Aggregate Bin, Lockout Tagout is required.

This process begins in the Vent Shaft MCC

Vent Shaft MCC Right Side Control Panel Door

Meikle Backfill Materials Supply System Faults

NOTE: Before clearing any faults determine the cause, log the fault (Date, Time, Fault, and Cause) then turn the log into the supervisor at the end of shift unless the fault creates a hazard to personnel. If the fault creates a hazard to personnel the system must be locked out tagged out, barricaded if necessary and reported immediately.

Conveyor Belt Pull Cord Fault 860 Level Not Ready Conveyor Belt Misalignment Fault System Plugged Heartbeat Fault to the 860 925 Dust Collector Fail to Start Heartbeat Fault to the 1075 Conveyor Plugged Conveyor Motion Fault


Meikle Backfill Aggregate Supply inspection

Inspect the roadways and walkways to ensure safe access, 30 CFR 56.11001, and egress out from the area. Inspect the ramp retaining blocks for movement or damage.

Depicts Retaining Wall Movement After Ramp Clean-Up Project

Spray Bar Dust Suppression

Ensure safe ramp access, and inspect aggregate hopper for damage. Ensure spray bars are working properly for dust suppression. Inspect the aggregate hopper grizzly and ensure the heater is operating properly.

Red - Stop Filling Agg Belt not running Green - Ok to Fill Agg Belt Running Blue - Call Meikle Backfill Plant Operator

NOTE: When all three lights flash at the same time there is a system fault

Backfill Control System Lights


Inspect Meikle Aggregate Supply Control Lights and confirm operation with Meikle Backfill Plant Operator. Inspect handrails, steps, and safety chains or swing gates on the catwalk. Report unsafe conditions to fixed

maintenance.

Catwalk with Control Panels, Remote Start, and Remote

Inspect fire extinguisher at the conveyor 30 CFR 57.4201. Inspect water lines, power cables, lighting, and housekeeping 30 CFR 57.20003. Inspect electrical outlets for damaged or missing covers. Inspect control boxes, cabling, and grommets. Report damaged components, exposed wires, and protective

jackets that are damaged or pulled from the panel grommets to the electrical department. Inspect labelling on control panels and disconnects, report deficiencies to the electrical department.

Control/Communications Panels and Remote Start/Stop with Remote Disconnect

Inspect communications for damage and test for communications with the Meikle Backfill Plant Operator and Meikle Dispatch Operator.

Inspect and ensure guarding is in place and undamaged on the conveyor, tail pulley, return idlers, return rollers, and head pulley.

Head Pulley View of Guarding Installed and In

Good Repair

Head Pulley Shaft Without Guarding NOTE: All Shafts

Must Be Guarded

The Same Head Pulley Shaft With Guarding Installed and

In Good Repair


Inspect access panels on the aggregate hopper and head pulley to ensure they are in place, bolted down, and undamaged.

Head Pulley Access Door Used for Belt Scraper Maintenance, Belt Maintenance, and Placement of the Pipe Plug when

Head Pulley Access Panel Full View Performing Maintenance in the Agg Bin. NOTE: Lockout Tagout Required Before Opening Access Panels

Open the head pulley access panel on the aggregate belt and inspect for evidence of plugging and/or ensure safety plug is removed before operation. Lockout Tagout required before opening access doors. See Lockout Tagout Policy #11-015

Grease the head pulley and tail pulley, 2 grease points each and 2 pumps per shift.

Head Pulley Grease Points One Grease Zerk On Each Front Upright Of The Agg Belt

Tail Pulley Grease Points One On/Near Belt Tensioners

Inspect the gearbox for 90w oil leakage, ensure drive belt is on both pulleys and in good repair, and drive belt guard is in place and undamaged.

Head Pulley Gear Box no Guards

Head Pulley Drive Belts and Guard

Head Pulley Gear Box

Guarded

Head Pulley Drive Assy.


Inspect the side limit switches in the middle of the belt for clearance.

Belt Travel Side Limit Switch Safety Device

Aggregate Belt Approximately Midline

Inspect and test the emergency stop pull cords on both sides of the conveyor.

Pull Cord Safety in Correct Position

Pull Cord Safety After Being Tripped

Meikle Backfill Aggregate Supply Operation

Use the remote start button at the conveyor and listen for the horn to sound. If the horn does not sound stop and call the electrical department for repairs.

Remote Start Switch Located at Agg Belt


Ensure the conveyor belt is moving freely with no drive belt squeal, improper drive motor noise, head pulley noise, or tail pulley noise.

Ensure return idlers and return rollers are turning freely and there is no side travel in the conveyor belt.

Tail Pulley Assembly Rollers and Return Idlers Drive Motor, Gearbox, and Drive Belt Assembly

Red Light

Stop Filling; do not fill if the red light is on under any circumstance. Personnel could be working in the Aggregate Bin and the system is required to be locked out and tagged out by all personnel during these conditions. Or the Aggregate Bin is at seventy five percent which is considered FULL there should always be a twenty five percent safety measure in case of a sensor or Aggregate Bin Bulkhead failure.

NOTE: If the "Red" light is on the Agg Belt should be stopped. If the "Red" light is on and the system still runs shut down immediately, Lock Out, Tag Out, Try Out, and report the deficiency to the shift supervisor. Failure to follow these instructions could result in serious or fatal injuries to personnel, environmental deviation, or damage to property.

Green Light

Ok to Fill; under green light conditions there should be no faults in the system and the Meikle Backfill Plant Operator is telling you the Aggregate Bin is under seventy five percent, proceed to operate the conveyor under normal conditions. Take care not to hit the bumper wall at the grizzly with the front wheels of the loader. This will cause damage to the front axle and pumpkin gears on the loader.

Blue Light

Call Meikle Backfill Plant Operator; be sure to stop the conveyor when you call the Meikle Backfill Plant Operator.

System Fault-

If all three lights come on at the same time (Red, Green, and Blue) there is a system fault that needs to be addressed.


While loading the Aggregate Hopper take care not to spill aggregate over the sides. Aggregate can get caught on the belt and cause equipment damage and/or belt fire.

Proper Hopper Loading Will Help Prevent Damage To The Tail Pulley

While loading the Aggregate Hopper always drive to conditions, maintain safe operating speeds, and maintain control of the equipment 30 CFR 56.9101

Do not run into the retaining blocks while operating the loader. Failure to follow these instructions could result in serious or fatal injuries to personnel, or damage to property.

Ensure water sprays are operating correctly while dumping aggregate. If not stop work immediately and repair.


When Cement and Fly Ash deliveries are being made ensure that the delivery driver is not allowing the pop off valves at the top of the silos to emit Cement and/or Fly Ash into the atmosphere. This is a violation of Barrick's EPA Clean Air Act Title V permit. Stop the act and report deviations to the shift Supervisor or Environmental group immediately.

After receiving the Red Light from the Meikle Backfill Plant Operator return to the remote start panel and shut down the conveyor.

Call the Meikle Backfill Plant Operator and verify Red Light conditions.


Meikle Backfill Aggregate Supply Post-Operation Inspection

Inspect roadways and walkways to ensure safe access, 30 CFR 56.11001, and egress out from the area. Inspect the ramp retaining blocks for movement or damage. Ensure safe ramp access, and inspect aggregate hopper for damage. Ensure spray bars are working properly for dust suppression. Inspect the aggregate hopper grizzly and ensure the heater is operating properly. Inspect handrails, steps, and safety chains or swing gates on the catwalk. Report unsafe conditions to fixed

maintenance. Inspect water lines, power cables, lighting, and housekeeping 30 CFR 57.20003. Inspect control boxes, cabling, and grommets. Report damaged components, exposed wires, and protective

jackets that are damaged or pulled from the panel grommets to the electrical department. Never make adjustments to the conveyor speed, electrical components, or conveyor components. All

adjustments and/or repairs are to be carried out by qualified personnel only. Inspect and ensure guarding is in place and undamaged on the conveyor, tail pulley, return idlers, return rollers,

and head pulley. Never remove guards, barricades, or access panels to repair or clean the conveyor unless Lock Out, Tag Out, Try

Out has been completed by all personnel working in the area. Failure to follow these instructions could result in serious or fatal injuries to personnel, environmental deviation, or damage to property.

Inspect access panels on the aggregate hopper and head pulley to ensure they are in place, bolted down, and undamaged.

Inspect the gearbox for 90w oil leakage, ensure drive belt is on both pulleys and in good repair, and drive belt guard is in place and undamaged.

Inspect the side limit switches in the middle of the belt for clearance. Inspect and test the emergency stop pull cords on both sides of the conveyor. Note deficiencies on your inspection card, report deficiencies to the proper department, and to the shift

supervisor. In cases where deficiencies create a hazard to personnel return to the Meikle Vent Shaft MCC turn disconnect/disconnects to the off position and Lock Out, Tag Out, Try Out.

Before reaching a rating of "Competent Operator" and receiving a 5000-23 for operation of the Meikle Backfill Materials Supply System, the Meikle Backfill Surface Support Operator must be able to complete these training procedures without; injuries to self or other personnel, environmental deviations which would violate Barrick's EPA Clean Air Act Title V permit, damage to property, and must achieve production targets of approximately 100 buckets of aggregate per shift or approximately 1500 tons per day.

NOTE: Most of the Federal Regulations cited in this training are found in MSHA's 13 rules to live by!

Every Person Going Home Safe And Healthy Every Day!


CEMA Document: SC 2004-01

WARNING AND SAFETY REMINDERS FOR SCREW , DRAG , AND BUCKET ELEVATOR CONVEYORS APPROVED FOR DISTRIBUTION BY THE SCREW CONVEYOR SECTION OF THE

CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION (CEMA) It is the responsibility of the contractor, instal ler, owner and user to instal l , maintain and operate the conveyor, components and, conveyor assemblies in such a manner as to comply with the Williams-Steiger Occupational Safety and Health Act and with all state and local laws and ordinances and the American National Standards Institute (ANSI) B20.1 Safety Code.

In order to avoid an unsafe or hazardous condition, the assemblies or parts must be installed and operated in accordance with the following minimum provisions.

1. Conveyors shall not be operated unless all covers and/or guards for the conveyor and drive unit are in place. If the conveyor is to be opened for inspection cleaning, maintenance or observation, the electric power to the motor driving the conveyor must be LOCKED OUT in such a manner that the conveyor cannot be restarted by anyone; however remote from the area, until conveyor cover or guards and drive guards have been properly replaced.

2. If the conveyor must have an open housing as a condition of its use and application, the entire conveyor is then to be guarded by a railing or fence in accordance with ANSI standard B20.1.(Request current edition and addenda)

3. Feed openings for shovel, front loaders or other manual or mechanical equipment shall be constructed in such a way that the conveyor opening is covered by a grating. If the nature of the material is such that a grating cannot be used, then the exposed section of the conveyor is to be guarded by a railing or fence and there shall be a warning sign posted.

4. Do not attempt any maintenance or repairs of the conveyor until power has been LOCKED OUT.

5. Always operate conveyor in accordance with these instructions and those contained on the caution labels affixed to the equipment.

6. Do not place hands, feet, or any part of your body, in the conveyor.

7. Never walk on conveyor covers, grating or guards.

8. Do not use conveyor for any purpose other than that for which i t was intended.

9. Do not poke or prod material into the conveyor with a bar or stick inserted through the openings.

10. Keep area around conveyor drive and control station free of debris and obstacles.

11. Eliminate all sources of stored energy (materials or devices that could cause conveyor components to move without power applied) before opening the conveyor

12. Do not attempt to clear a jammed conveyor unti l power has been LOCKED OUT.

13. Do not attempt field modification of conveyor or components.

14. Conveyors are not normally manufactured or designed to handle materials that are hazardous to personnel. These materials which are hazardous include those that are explosive, f lammable, toxic or otherwise dangerous to personnel. Conveyors may be designed to handle these materials. Conveyors are not manufactured or designed to comply with local, state or federal codes for unfired pressure vessels. If hazardous materials are to be conveyed or if the conveyor is to be subjected to internal or external pressure, manufacturer should be consulted prior to any modifications.

CEMA insists that disconnecting and locking out the power to the motor driving the unit provides the only real protection against injury. Secondary safety devices are available; however, the decision as to their need and the type required must be made by the owner-assembler as we have

no information regarding plant wiring, plant environment, the interlocking of the screw conveyor with other equipment, extent of plant automation, etc. Other devices should not be used as a substitute for locking out the power prior to removing guards or covers. We caution that use of the secondary devices may cause employees to develop a false sense of security and fail to lock out power before removing covers or guards. This could result in a serious injury should the secondary device fail or malfunction.

There are many kinds of electrical devices for interlocking of conveyors and conveyor systems such that if one conveyor in a system or process is stopped other equipment feeding it, or following it can also be automatically stopped.

Electrical controls, machinery guards, rai l ings, walkways, arrangement of installation, training of personnel, etc., are necessary ingredients for a safe working place. I t is the responsibi l i ty of the contractor, installer, owner and user to supplement the materials and services furnished with these necessary items to make the conveyor installation comply with the law and accepted standards.

Conveyor inlet and discharge openings are designed to connect to other equipment or machinery so that the flow of material into and out of the conveyor is completely enclosed.

One or more warning labels should be visible on conveyor housings, conveyor covers and elevator housings. If the labels attached to the equipment become i l legible, please order replacement warning labels from the OEM or CEMA.

The Conveyor Equipment Manufacturers Association (CEMA) has produced an audio-visual presentation entitled Safe Operation of Screw Conveyors, Drag Conveyors, and Bucket Elevators. CEMA encourages acquisition and use of this source of safety information to supplement your safety program.

SEE OTHER SIDE FOR SAFETY LABELS

NOTICE: This document is provided by CEMA as a service to the industry in the interest of promoting safety. It is advisory only and it is not a substitute for a thorough safety program. Users should consult with qualified engineers and other safety professionals. CEMA makes no representations or warranties, either expressed or implied, and the users of this document assume full responsibility for the safe design and operation of equipment.

CEMA Document: SC 2004-01

CEMA Safety Labels The CEMA safety labels shown below should be used on screw conveyors, drag conveyors, and bucket elevators. Safety labels should be placed on inlets, discharges, troughs, covers, inspection doors & drive guards. See CEMA Safety Label Placement Guidelines on CEMA Web Site: http://www.cemanet.org/safety/guidelines.html

CHR930001

Exposed moving parts can causesevere injury

LOCK OUT POWER before removingguard

http://www.cemanet.org

CHS991026

Walking or standing on conveyor covers or gratings can cause severe injury

STAY OFF http://www.cemanet.org

CVS930010

Exposed conveyors and moving parts can cause severe injury

LOCK OUT POWER before removing cover or servicing


CVS930012

Exposed buckets and moving parts can cause severe injury



WARNING Exposed screw andmoving parts can causesevere injury

LOCK OUT POWER before removingcover or servicing

CHR930011 http://www.cemanet.org

CVS930011

Exposed screw and moving parts can cause severe injury



PROMINENTLY DISPLAY THESE

SAFETY LABELS ON

INSTALLED EQUIPMENT

SEE OTHER SIDE FOR SAFETY REMINDERS

Note: Labels alone do not substitute for a thorough in-plant safety training program centered on the hazards

associated with operating your installed equipment.

Contact CEMA or Your Equipment Manufacturer for Replacement Labels

CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION 6724 Lone Oak Blvd., Naples, Florida 34109

239-514-3441 Http://www.cemanet.org

http:Http://www.cemanet.orghttp://www.cemanet.org/safety/guidelines.html

Fatality #18 - October16, 2010 Powered Haulage - Kansas - Limestone, Crushed and Broken N R Hamm Quarry Inc - Plant #80013

METAL/NONMETAL MINE FATALITY - On October 16, 2010, a 52 year- old haul truck driver with 5 years of experience died at a crushed stone operation. He was using an air-powered hammer/chisel to clean hardened material on a belt conveyor tail pulley. The victim was positioned on top of the return side of the belt conveyor, facing the tail pulley, when the belt conveyor was energized, entangling him in the tail pulley.

Best Practices

Deenergize and block belt conveyors against motion before working near a drive, head, tail, and take-up pulleys.

Lock-out/tag-out all energy sources to belt conveyors before working on them.

Establish policies and procedures for conducting specific tasks on belt conveyors.

Ensure that persons are task trained and understand the hazards associated with the work being performed.

Maintain communications with all persons performing the task. Before re-starting belt conveyors, ensure that all persons are clear.

This is the 18th fatality reported in calendar year 2010 in the metal and nonmetal mining industries. As of this date in 2009, there were 16 fatalities reported in these industries. This is the 4th Powered Haulage fatality in 2010. There were 5 Powered Haulage fatalities in the same period in 2009.

The information provided in this notice is based on preliminary data ONLY and does not represent final determinations regarding the nature of the incident or conclusions regarding the cause of the fatality.

DIS CLAIMER

Men tion of any com pany or prod uct does not con sti tute en dorse ment by the Na tional In sti tute for Oc cu pa tional Safety and Health.

This docu ment is in the pub lic do main and may be freely cop ied or re printed.

Copies of this and other NIOSH doc u ments are avail able from

Na tional In sti tute for Oc cu pa tional Safety and Health Pub li ca tions Dis sem i na tion 4676 Co lum bia Park way

Cincinnati, OH 452261998

Fax num ber: (513) 5338573 Tele phone num ber: 180035NIOSH (18003564674)

E-mail: [email protected]

To re ceive other in for ma tion about oc cu pa tional safety and health prob lems, call 180035NIOSH (18003564674), or visit the NIOSH Web site at

www.cdc.gov/niosh

DHHS (NIOSH) Pub li ca tion No. 99110

July 1999

www.cdc.gov/nioshmailto:[email protected]

Preventing Worker Deaths from Uncontrolled Release of Electrical, Mechanical, and Other Types of Hazardous Energy

WARNING! Workers who install or service equipment and systems may be

injured or killed by the uncontrolled release of hazardous energy.

Take the fol low ing steps to pro tect your self if you in stall or ser vice equip ment and sys tems:

Fol low OSHA reg u la tions. Iden tify and la bel all sources of haz ard ous

en ergy.

Be fore be gin ning work, do the fol low ing:

1. De-energize all sources of hazardous energy: Dis con nect or shut down en gines or

mo tors. De-energize elec tri cal cir cuits. Block fluid (gas or liq uid) flow in

hy drau lic or pneu matic sys tems. Block ma chine parts against mo tion.

2. Block or dissipate stored energy:

Dis charge ca pac i tors. Re lease or block springs that are

un der com pres sion or ten sion. Vent flu ids from pres sure ves sels,

tanks, or ac cu mu la tors but never vent toxic, flam ma ble, or ex plo sive sub stances di rectly into the atmosphere.

3. Lockout and tagout all forms of hazardous energy including electrical breaker panels, control valves, etc.

4. Make sure that only one key exists for each of your assigned locks and that only you hold that key.

5. Verify by test and/or observation that all energy sources are de-energized.

6. Inspect repair work before removing your lock and activating the equipment.

7. Make sure that only you remove your assigned lock.

8. Make sure that you and your coworkers are clear of danger points before re-energizing the system.

Par tic i pate in all train ing pro grams of fered by your em ploy ers.

Re printed with per mis sion of IDESCO Cor po ra tion, 1999.

Only the worker who in stalls a lock and tag should re move them af ter work is com plete and in spected.

Please tear out and post. Dis trib ute cop ies to work ers. See back of sheet to or der com plete Alert.

For ad di tional in for ma tion, see NIOSH Alert: Pre venting Worker In juries and Deaths from Haz ard ous En ergy Re lease [DHHS (NIOSH) Pub li ca tion No. 99110. Sin gle cop ies of the Alert are available free from the fol low ing:

Na tional In sti tute for Oc cu pa tional Safety and Health Pub li ca tions Dis sem i na tion 4676 Co lum bia Park way

Cincinnati, OH 452261998

Fax num ber: (513) 5338573 Phone num ber: 180035NIOSH (18003564674)

E-mail: [email protected]

U.S. De part ment of Health and Hu man Ser vices Pub lic Health Ser vice

Cen ters for Dis ease Con trol and Pre ven tion Na tional In sti tute for Oc cu pa tional Safety and Health

mailto:[email protected]

Pre venting Worker Deaths from Un con trolled Re lease of Elec tri cal, Me chan i cal, and Other Types of Haz ard ous En ergy

WARNING! Workers who install or service equipment and systems may be

injured or killed by the uncontrolled release of hazardous energy.

The Na tional In sti tute for Oc cu pa tional Safety and Health (NIOSH) re quests assistance in pre vent ing the death or in jury of work ers ex posed to the un expected or un con trolled re lease of hazard ous en ergy. In this Alert, haz ard ous en ergy is any type of en ergy in suf ficient quan tity to cause in jury to a worker. Com mon sources of haz ard ous en ergy in clude elec tric ity, me chan i cal mo tion, pres sur ized air, and hot and cold tem per a tures. Haz ard ous en ergy re leases may oc cur dur ing the in stal lation, main te nance, ser vice, or re pair of ma chines, equip ment, pro cesses, or sys tems. In ves ti ga tions con ducted as part of the NIOSH Fa tal ity As sess ment and Con trol Eval u a tion (FACE) Program sug gest that de vel op ing and follow ing haz ard ous en ergy con trol pro ce dures could pre vent worker injuries and fa tal i ties.

This Alert de scribes five fa tal in ci dents in which work ers con tacted un controlled haz ard ous en ergy dur ing in stalla tion, main te nance, ser vice, or re pair work. To pre vent such deaths, the rec om men da tions in this Alert should be fol lowed by ev ery em ployer, man ager,

su per vi sor, and worker who in stalls, main tains, ser vices, or re pairs machines, equip ment, pro cesses, or systems. NIOSH re quests that trade jour nal ed i tors, safety and health of fi cials, and oth ers re spon si ble for worker safety and health bring this Alert to the at tention of em ploy ers and work ers who are at risk.

Re printed with per mis sion of IDESCO Cor po ra tion, 1999.

Only the worker who in stalls a lock and tag should re move them af ter work is com plete and in spected.

1

BACK GROUND

Num ber of Workers Killed No de tailed na tional data are avail able on the num ber of work ers killed each year by con tact with un con trolled haz ard ous en ergy. How ever, dur ing the pe riod 19821997, NIOSH in ves ti gated 1,281 fa tal in ci dents as part of their FACE Pro gram. Of these, 152 involved in stal la tion, main te nance, ser vice, or re pair tasks on or near ma chines, equip ment, pro cesses, or sys tems. Be cause the FACE pro gram was ac tive in only 20 States be tween 1982 and 1997, these fa tal i ties repre sent only a por tion of the U.S. work ers who were killed by con tact with un controlled haz ard ous en ergy.

Con trib uting Fac tors Re view of these 152 in ci dents sug gests that three re lated fac tors con trib uted to these fa tal i ties:

Fail ure to com pletely de-energize, iso late, block, and/or dis si pate the en ergy source (82% of the in ci dents, or 124 of 152)

Fail ure to lock out and tagout en ergy con trol de vices and iso la tion points af ter de-energization (11% of the in ci-dents, or 17 of 152)

Fail ure to ver ify that the en ergy source was de-energized be fore be gin ning work (7% of the in ci dents, or 11 of 152)

In a study con ducted by the United Auto Workers (UAW), 20% of the fa tal i ties (83 of 414) that oc curred among their members be tween 1973 and 1995 were attributed to in ad e quate haz ard ous en ergy con trol pro ce dures spe cif i cally, lock out/tagout proce dures. The en ergy sources in volved in

these fa tal i ties in cluded ki netic, po ten tial, elec tri cal, and ther mal en ergy [UAW 1997].

CUR RENT OSHA REG U LA TIONS

Cur rent Oc cu pa tional Safety and Health Ad min is tra tion (OSHA) stan dards for general in dus try are es tab lished to prevent inju ries and fa tal i ties from con tact with haz ard ous en ergy [29 CFR* 1910.147]. This stan dard re quires em ploy ers to es tab lish a pro gram con sist ing of en ergy con trol pro ce dures, em ployee train ing and pe ri odic in spec tions to en sure that be fore any em ployee per forms any ser vic ing or main te nance on a ma chine or equip ment where the un ex pected en er giz ing, start up or re lease of stored en ergy could oc cur and cause in jury, the ma chine or equipment shall be iso lated from the en ergy source, and ren dered in op er a tive.

Other OSHA stan dards for gen eral in dus try cite the need for de-energizing elec tri cal en ergy and lock ing and tag ging elec tri cal cir cuits and equip ment be fore per form ing main te nance and ser vic ing tasks. The fol low ing OSHA stan dards con tain lockout/tagout-related re quire ments:

1910.146 Per mit-Required Con fined Spaces

1910.177 Ser vicing Multi-Piece and Sin gle Piece Rim Wheels

1910.178 Powered In dus trial Trucks

1910.179 Over head and Gan try Cranes

* Code of Fed eral Reg u la tions . See CFR in ref er ences.

Haz ard ous En ergy 2

1910.181 Der ricks

1910.213 Woodworking Ma chin ery

1910.217 Me chan i cal Power Presses

1910.218 Forging Ma chines

1910.261 Pulp, Pa per, and Pa per board Mills

1910.262 Textiles

1910.263 Bak ery Equip ment

1910.265 Saw mills

1910.269 Elec tric Power Gen er a tion, Trans mis sion, and Dis tri bu tion

1910.272 Grain Han dling

1910.305 Wiring Methods, Com po nents, and Equip ment for Gen eral Use

1910.306 Spe cific Pur pose Equip ment and In stal la tions

1910.333 Se lec tion and Use of Work Prac tices

OSHA stan dards for con struc tion also con tain re quire ments for pro tect ing work ers from elec tri cal haz ards [29 CFR 1926.416 and 29 CFR 1926.417]. These stan dards re quire that work ers ex posed to any part of an elec tri cal power cir cuit be pro tected through de-energizing and ground ing of the cir cuit or through ap pro pri ate guard ing. These stan dards also re quire that all de-energized cir cuits be ren dered in op er able and tagged out.

Haz ard ous En ergy

FORMS OF HAZ ARD OUS EN ERGY

Workers may be ex posed to haz ard ous energy in sev eral forms and com bi na tions dur ing in stal la tion, main te nance, ser vice, or re pair work. A com pre hen sive haz ardous en ergy con trol pro gram should address all forms of haz ard ous en ergy [NIOSH 1983]:

Ki netic (me chan i cal) en ergy in the mov ing parts of me chan i cal sys tems

Po ten tial en ergy stored in pres sure ves sels, gas tanks, hy drau lic or pneu matic sys tems, and springs (po ten tial en ergy can be re leased as haz ard ous ki netic en ergy)

Elec tri cal en ergy from gen er ated elec tri cal power, static sources, or elec trical stor age de vices (such as bat ter ies or ca pac i tors)

Ther mal en ergy (high or low tem per a ture) re sult ing from me chan i cal work, ra di ation, chem i cal re ac tion, or elec tri cal re sis tance

CASE RE PORTS

As part of the FACE Pro gram from 1982 through 1997, NIOSH in ves ti gated 152 fatal in ci dents in which work ers con tacted un con trolled haz ard ous en ergy. The fol lowing case re ports sum ma rize five of these in ves ti ga tions.

Case No. 1 Uncontrolled Ki netic En ergy A 25-year-old male worker at a con crete pipe man u fac tur ing fa cil ity died from in ju ries

3

he re ceived while clean ing a rib bon-type con crete mixer. The vic tims daily tasks included clean ing out the con crete mixer at the end of the shift. The clean-out pro ce dure was to shut off the power at the breaker panel (ap prox i mately 35 feet from the mixer), push the tog gle switch by the mixer to make sure that the power was off, and then en ter the mixer to clean it.

No one wit nessed the event, but in ves ti gators con cluded that the mixer op er a tor had shut off the main breaker and then made a tele phone call in stead of fol low ing the nor mal pro ce dure for check ing the mixer be fore any one en tered it. The vic tim did not know that the op er a tor had de-energized the mixer at the breaker. Thinking he was turn ing the mixer off, he ac ti vated the breaker switch and en er gized the mixer. The vic tim then en tered the mixer and be gan clean ing with out first push ing the tog gle switch to make sure that the equip ment was de-energized. The mixer op er a tor re turned from mak ing his tele phone call and pushed the tog gle switch to check that the mixer was de-energized. The mixer started, and the op er a tor heard the vic tim scream. He went im me di ately to the main breaker panel and shut off the mixer.

Within 30 min utes, the emer gency med i cal ser vice (EMS) trans ported the vic tim to a lo cal hos pi tal and then to a lo cal trauma cen ter. He died ap prox i mately 4 hours later [NIOSH 1995].

Case No. 2 Un con trolled Elec tri cal En ergy

A 53-year-old jour ney man wireman was elec tro cuted when he con tacted two energized, 6.9 -kilo volt buss ter mi nals. The vic tim and two co work ers (all con tract employees) were in stall ing elec tri cal

com po nents of a sul fur di ox ide emis sion con trol sys tem in a 14-compartment switch house.

The cir cuit breaker pro tect ing the in ter nal buss within the switch house had been trip ped out and marked with a tag but it had not been se cured by lock ing. This pro ce dure was con sis tent with the haz ard ous en ergy con trol pro ce dures of the power plant.

The vic tim and his co work ers were wip ing down the in di vid ual com part ments be fore a prestartup in spec tion by power plant per son nel. With out the knowl edge of the vic tim and his co work ers, power plant per son nel had en er gized the in ter nal buss in the switch house. When the vic tim be gan to wipe down one of the com part ments at the south end of the switch house, he con tacted the A-phase buss ter mi nal with his right hand and the C-phase buss ter mi nal with his left hand. This act com pleted a path be tween phases, and the vic tim was elec tro cuted.

A coworker walk ing past the vic tim dur ing the in ci dent was blown back ward by the arc ing and re ceived first-degree flash burns on his face and neck. A sec ond coworker at the north end of the switch house heard the ex plo sion and came to help. He no ti fied the con trac tors safety co or di na tor by ra dio and re quested EMS. The EMS re sponded in about 15 min utes and trans ported the vic tim to a lo cal hos pital emer gency room where he was pronounced dead [NIOSH 1994].

A con duct ing bar, rod, or tube that car ries heavy cur rents to sup ply sev eral elec tric cir cuits.


Case No. 3 Un con trolled Ki netic En ergy

A 38-year-old worker at a county san i tary land fill died af ter fall ing into a large trash com pac tor used to bale card board for recycling. The card board was lifted 20 feet by a belt con veyor and fed through a 20by 44-inch open ing into a hop per. The hopper had au to matic con trols that ac tivated the baler when enough ma te rial col lected in the bal ing cham ber. When the baler was ac ti vated, ma te rial in the cham ber was com pressed by a ram that en tered the cham ber from the side. Ex cess ma terial above the cham ber was trimmed by a shearer.

On the day of the in ci dent, card board jammed at the con veyor dis charge open ing. With out stop ping, de-energizing, or lock ing out the equip ment, the vic tim rode the con veyor up to the dis charge open ing to clear the jam. He fell into the hop per and the bal ing cy cle was au to mat i cally ac tivated, am pu tat ing his legs. The vic tim bled to death be fore he could be re moved from the ma chine [Col o rado De part ment of Public Health and En vi ron ment 1994].

Case No. 4 Un con trolled Po ten tial En ergy

The 32-year-old owner of a heavy equipment main te nance busi ness died af ter a wheel and tire as sem bly ex ploded dur ing re pair work. The vic tim was re mov ing the as sem bly from a test roller when it exploded and struck him with the fly ing split rim of the wheel.

The test roller was a large, two-wheeled cart that car ried about 60,000 pounds of con crete weights. The roller was used in high way con struc tion to test road sur faces for proper com pac tion.

Haz ard ous En ergy

The vic tim had been work ing as a sub contrac tor to re pair the wheel and tire as sembly, which had been smok ing ear lier in the day and was be lieved to be rub bing against the con crete weights. The as sem bly con sisted of a two-piece out side rim and an inside ring re tainer that was held to gether and mounted on the axle by 20 wheel bolts and nuts. Nor mal air pres sure for the mounted tire was 70 psi.

The vic tim raised and blocked the roller. With out dis charg ing the air from the tire and us ing no per sonal pro tec tive equipment, he be gan to re move the wheel nuts us ing a pneu matic im pact wrench. He had no train ing or ex pe ri ence with this type of work or in the ser vic ing of this type of wheel. He did not re al ize that only some of the bolts held the wheel tire as sem bly to the axle. The re main der held the outer half of the rim to the in side half, se cur ing the tire to the wheel. As the vic tim re moved the nine teenth wheel nut, the pres sur ized air in the tire dis charged ex plo sively, caus ing the split rim to fly off the wheel and strike him. He died from ce re bral con tu sions and lac er a tions [Min ne sota De part ment of Health 1992].

Case No. 5 Uncontrolled Ki netic and Ther mal En ergy

A 33-year-old jan i to rial worker died af ter he was trapped in side a linen dryer at a hos pi tal laun dry while clean ing plas tic debris from the in side of the dryer drum. The clean ing task (which usu ally took 15 min utes to an hour) in volved prop ping open the door to the dryer with a piece of wood and en ter ing the 4- by 8-foot dryer drum. The melted de bris was re moved by scrap ing and chis el ing it with screw driv ers and chis els. The dryer was part of an au to-mated sys tem that de liv ered wet laun dry from the washer through an over head

5

conveyor to the dryer, where it was dried during a 6-minute cy cle with air tem per atures of 217E to 230EF. The sys tem con trol panel was equipped with an er ror light that was ac ti vated if the dryer door was open, in di cat ing that the dryer was out of ser vice.

On the night of the in ci dent, the vic tim propped the door open and en tered the dryer drum with out de-energizing or locking out the dryer. He be gan to clean the inside of the drum. Al though the er ror light had been ac ti vated when the door was propped open, the sig nal was misinterpreted by a coworker, who restarted the sys tem. When the sys tem was restarted, the over head con veyor de liv ered a 200-pound load of wet laun dry to the dryer knock ing out the wooden door prop, trap ping the vic tim in side, and automatically start ing the dry ing cy cle. The victim remained trapped in side un til the cy cle was com pleted and was dis cov ered when the load was dis charged from the dryer. He died thirty min utes later of se vere burns and blunt head trauma [Mas sa chu setts De part ment of Pub lic Health 1992].

CON CLU SIONS

Re view of the NIOSH FACE data in di cates that three re lated fac tors con trib ute to in ju ries and deaths that oc cur when work ers per form in stal la tion, main te nance, service, or re pair work near haz ard ous energy sources:

Fail ure to com pletely de-energize, iso late, block, and/or dis si pate the hazard ous en ergy source

Fail ure to lockout and tagout en ergy con trol de vices and iso la tion points af ter the haz ard ous en ergy source has been de-energized

Fail ure to ver ify that the haz ard ous en ergy source was de-energized be fore be gin ning work

These fa tal i ties could have been pre vented if com pre hen sive haz ard ous en ergy control pro ce dures had been im ple mented and fol lowed.

REC OM MEN DA TIONS

NIOSH rec om mends that em ploy ers imple ment the fol low ing steps to pre vent in juries and deaths of work ers who must work with haz ard ous en ergy in their jobs:

1. Com ply with OSHA reg u la tions.

2. De velop and im ple ment a haz ard ous en ergy con trol pro gram.

3. Iden tify and la bel all haz ard ous en ergy sources.

4. De-energize, iso late, block, and/or dissi pate all forms of haz ard ous en ergy be fore work be gins.

5. Es tab lish lock out/tagout pro grams that

re quire work ers to se cure en ergy con trol de vices with their own in divid u ally as signed locks and keys only one key for each lock the worker con trols;

Use of mas ter keys should be re served for unusual cir cum stances when the worker is ab sent from the work place. How ever, if mas ter keys are nec es sary, keep them un der su per vi sory con trol. List the proper pro ce dures for us ing them in the writ ten pro gram for con trol ling haz ard ous en ergy.


re quire that each lock used to se cure an en ergy con trol de vice be clearly la beled with du ra ble tags to iden tify the worker as signed to the lock;

make sure that the worker who in stalls a lock is the one who removes it af ter all work has been com pleted; and

if work is not com pleted when the shift changes, work ers ar riv ing on shift should ap ply their locks before de part ing work ers re move their locks.

6. Ver ify by test and/or ob ser va tion that all en ergy sources are de-energized be fore work be gins.

7. In spect re pair work be fore re ac ti vat ing the equip ment.

8. Make sure that all work ers are clear of dan ger points be fore re-energizing the sys tem.

9. Train ALL work ers in the ba sic concepts of haz ard ous en ergy con trol.

10. In clude a haz ard ous en ergy con trol pro gram with any con fined-space en try pro gram.

11. En cour age man u fac tur ers to de sign ma chines and sys tems that make it easy to con trol haz ard ous en ergy.

These rec om men da tions are de scribed in more de tail in the fol low ing sec tions.

1. Com ply with OSHA reg u la tions. Em ployers and work ers must com ply with OSHA reg u la tions for con trol ling haz ardous en ergy dur ing main te nance and in stallation

work (see 29 CFR 1910.146, 1910.147, 1910.177, 1910.178, 1910.179, 1910.181, 1910.213, 1910.217, 1910.218, 1910.261, 1910.262, 1910.263, 1910.265, 1910.269, 1910.272, 1910.305, 1910.306, 1910.333, 1926.416, and 1926.417). OSHA standards and accepted safe work prac tices require em ploy ers to en sure that all haz ardous en ergy sources are de-energized before work be gins. If these sources can not be de-energized, OSHA re quires em ploy ers to pro tect work ers with in su la tion, guard ing, and ap pro pri ate per sonal pro tec tive equip ment.

2. Im ple ment a haz ard ous en ergy con trol pro gram.

Em ployers should de velop and im ple ment a writ ten haz ard ous en ergy con trol program that, at a min i mum,

de scribes safe work pro ce dures,

es tab lishes for mal lock out/tagout pro ce dures,

trains all em ploy ees in the pro gram, and

en forces the use of the pro ce dures (in clud ing dis ci plin ary ac tion for fail ure to fol low them).

Haz ard ous en ergy con trol pro grams should out line the fol low ing safe work prac tices:

Iden tify tasks that may ex pose work ers to haz ard ous en ergy.

Iden tify and de-energize all haz ard ous en ergy sources, in clud ing those in ad ja cent equip ment.


Lock out and tagout all en ergy-isolating de vices to pre vent in ad ver tent or un au-tho rized re ac ti va tion or startup.

Iso late, block, and/or dis si pate all haz ard ous sources of stored or re sid ual en ergy, in clud ing those in ad ja cent equip ment.

Be fore be gin ning to work, ver ify en ergy iso la tion and de-energization, in cludin

Documents

Meikle Backfill Materials Supply System Operator Manual