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REPORT OF FATAL ACCIDENT 2000

Name of Victim:William Foster
Address:McConnelsburg
Name of Mine:New Hope Crushed Stone Quarry
Mine Type:Industrial Minerals Surface
Permit No.:7974SM3
License No.:1879
County:Bucks
Municipality:Solebury
Name of Company:New Hope Crushed Stone & Limestone Co.
Date of Accident:April 12, 2000

DESCRIPTION OF THE ACCIDENT

On April 12, 2000, at approximately 5:00 p.m., William Foster, age 38, employed as a laborer for Kinsley Construction, Inc., subcontractor to Mellot Enterprises, Inc., the primary plant construction contractor, was fatally injured. The victim was assigned to work with a service technician from H.B. Mellot Estate, Inc., another subcontractor, tracking belts on conveyors. The victim was instructed on how to rack the return rollers and adjust conveyor belts by the service technician, and both individuals completed the tracking of the C13 conveyor without incident.

At approximately 3:55 p.m., both the victim and the service technician began working on the C10 conveyor belt. The service technician last observed the victim kneeling on the C10 conveyor walkway, reaching around the guarded area of the lower bend pulley. It is believed that the victim was cutting ties to the lubrication line on the bend pulley. Around 4:45 p.m., the service technician visually examined the C10 conveyor walkway to make sure it was free of personnel, and observing no one on the walkway, radioed James Minnichbach, Vice President, Mellot Enterprises, Inc., who was supervising the testing of the conveyor belts, that belt C10 could be started. The conveyor belt breaker immediately tripped when the conveyor belt was started, and the conveyor belt stopped after traveling approximately two to three feet.

Two contract (Gettle Electric) electrical employees, working at the 6614 cone crusher (below the C10 conveyor) then observed the victim caught between a bend pulley and the framework of the C10 conveyor and alerted other personnel on site.

Local police, rescue and emergency medical personnel were then summoned via 911, and personnel on site began efforts to free the victim. The guard on the bend pulleys was removed, and the conveyor belt was cut by the workers on site and the victim was removed. Emergency personnel then attended to the victim and transported him to the local hospital, where he was pronounced dead a short time later. The coroner’s report attributes the victim’s death to traumatic asphyxia due to compression of the chest, as a result of being caught in a conveyor belt.

CAUSE OF THE ACCIDENT

Although no one actually saw or witnessed the accident, evidence at the site and interviews with the victim’s co-workers indicate or leaves investigators to believe that the victim was cutting ties to the lubrication lines on the C10 conveyor bend pulley. Therefore, it appears that the main cause of the accident was management’s failure to implement a lock and tag out procedure for the C10 conveyor prior to working on it, and the failure of site personnel to ascertain the location of all co-workers working on that specific piece of equipment or machinery prior to the energizing of said equipment or machinery.

RECOMMENDATION

  1. Train and require all workers/laborers to implement a lock out and tag out procedure for all equipment, machinery and related controls.

  2. Install audible warning start up systems on all equipment and machinery.

  3. Instruct all workers/laborers to identify the location of all co-workers prior to the energizing of any equipment or machinery.

REPORT OF FATAL ACCIDENT 2000

Name of Victim:Jeff Cunko
Address:West Finley
Name of Mine:Bailey Deep Mine
Mine Type:Bituminous Underground Mine
Permit No.:30841316
License No.:4305
County:Greene
Municipality:Richhill
Name of Company:Consol PA Coal Co.
Date of Accident:October 29, 2000

DESCRIPTION OF THE ACCIDENT

On October 29, 2000, at approximately 12:35 a.m., the victim, age 50, a maintenance foreman, and two mechanics were in the process of removing slack from the bunker B-side conveyor chain. The victim was standing on the catwalk located above the conveyor drive torque arm. He was operating the control box jogging the conveyor so the mechanics could install dogs in the conveyor chain. They installed the first two dogs on the top chain and the victim jogged the conveyor two or three times toward the discharge end in an attempt to align the conveyor chain to install two additional dogs. When he attempted to jog the conveyor one more time, the weld holding the eyelet to an eight inch steel beam which secured the bunker B-side conveyor motor torque arm failed causing the torque arm to rotate up through a steel catwalk structure the victim was standing on, inflicting fatal injuries.

CAUSE OF THE ACCIDENT

This accident occurred due to the failure of the weld holding the eyelet to the eight inch steel beam imbedded in the concrete structure. During the investigation, it was determined that the eyelet had been relocated (cut off and re-welded by contractors installing the bunker). The weld used to relocate the eyelet displayed poor workmanship. The design of the anchoring system for the torque arm and motor contributed to the accident. A Safe Work Instruction (SWI) was not developed for taking slack out of the bunker chain at the time of the accident, but safe work practices were being followed.

RECOMMENDATION

  1. Redesign the anchoring system for the torque arm and motor.

  2. Any alteration of the equipment must have approval of a certified mechanical engineer and the manufacturer of the equipment being installed.

  3. Develop a SWI (Safe Work Instruction) for taking slack out of the bunker chain, and insure that all mechanics are adequately trained before performing this task.

  4. Only qualified welders shall be used in applications where torque or tension points are the only means of attachment.

REPORT OF FATAL ACCIDENT 2000

Name of Victim: Gary W. Kerley
Address:Blairsville
Name of Mine:Shade Creek Plant
Mine Type:Bituminous Preparation Plant
Permit No.:56841603
License No.:1231
County:Somerset
Municipality:Shade
Name of Company:PBS Coals, Inc.
Date of Accident:December 19, 2000

DESCRIPTION OF THE ACCIDENT

On December 19, 2000, at approximately 1:30 p.m., Gary Kerley, age 24, a contract truck driver, was fatally injured when he was crushed in the cab of his truck by the bed of another truck. The two trucks were parked adjacent to each other at the dumpsite. As the one truck raised its bed, the truck turned over on its side hitting the cab of the victim. The victim worked for D & D Truck Lines and was hauling coal to the Shade Creek Plant.

CAUSE OF THE ACCIDENT

The accident occurred because two tractor-trailers were dumping side-by-side, with the victim’s truck slightly offset to the rear. When one driver extended his trailer to the maximum height, the load failed to evenly discharge due to freezing. This caused the trailer to overturn on the cab of the victim, on full extension of the bed.

RECOMMENDATION

  1. While trucks are dumping, they should stay a safe distance apart.
  2. Agents should be used to keep materials from freezing in the bed of the truck.