Lessons Learned Dust Emphasis Team Inspections On-Shift ...

Lessons Learned Dust Emphasis Team Inspections On-Shift ...

Lessons Learned Dust Emphasis Team Inspections On-Shift Examinations By Roy Baker District 4 Health Supervisor Part 75 75.362 (a)(2) On-shift Examinations

Examination to assure compliance with respirable dust controls in the Approved Ventilation Plan Within 1 hour of shift change if there is no break in production (Hot-Seating) Prior to resuming production if there is a break in production at shift change Deficiencies corrected prior to production beginning or resuming 2 Part 75 75.362 (a)(2) On-shift Examinations

Examination includes: Air quantities and velocities Water pressures & flow rate Excessive leakage in water delivery system Water spray number and orientation Section ventilation & control device placement Work practices in plan Any other dust suppression measures 3

Part 75 75.362 (g)(2) On-shift Examinations Certified person conducting the on-shift examination to assure compliance with the respirable dust control parameters was not certifying by initials, date, and time that the examination was made. 4 Water Spray System Examination Sprays used were not approved in the plan

Water flow rate incorrect Pressure was not being checked on both sides of the Continuous Miner and multiple locations on Longwall Dirty sprays were producing an ineffective spray pattern Scrubber Examination Full Pitot Traverse checks of the scrubber were not being conducted and some folks did not know how to conduct the required checks or how to establish a centerline correlation factor

(Average velocity divided by centerline reading) for use throughout the week for a comparison depending on your plan requirements. Scrubber sprays were not being checked to make sure they were working and covering the entire area of the screen. Different size screens were being used besides what the plan required. Examples- 20 mesh,30 mesh, or bottle brush type Seals around screen doors and demister were missing or damaged. The bottom of sumps were found clogged. Deflector vents were damaged to keep from directing exhaust toward ribs and a few were found missing.

On-shift Parameter check of Roof Bolting Machines MSHA Approved Dust Hose INSPECTION AND MAINTENANCE - DUST HOSE, FITTINGS AND CLAMPS Check for and Fix Any Leaks Check for Hose Wear and Replace if Required

Hose Clamps Installed and Tight INSPECTION INSPECTION AND AND MAINTENANCE MAINTENANCE DUST DUST BOXES AND FILTER ELEMENTS... ELEMENTS... Door Door Latches Latches

If damaged replace with Fletcher OEM dust tank latch only. Doors Doors and and Door Door Gaskets Gaskets Doors not warped or bent All gaskets installed, in

good condition and clean. Each chamber must be separated. Check for air leaks and replace gasket if necessary. Use only OEM gaskets Filter Filter Elements Elements Hand tighten wing nut as tight as possible

Dust leakage around nut is possible if not tight Never attempt to clean filter elements. Remove and properly dispose of dirty element. Install new approved element when dust collection efficiency decreases to the point that drilling rate is reduced. Clean box area of dust before installing new clean filter or dust can contaminate clean side of system. Make sure filter sealing surface is clean

If dust bypasses filter, this cavity must be cleaned out or system will not operate properly. Cyclone Cap PN: 56362 MAKE SURE HOSES ARE CONNECTED CORRECTLY AIRFLOW DIRECTION ARROWS Roy Baker

District 4 Mt. Hope WV. PH# 304-877-3900 [email protected] LESSONS LEARNED DUST EMPHASIS TEAM INSPECTION FINDINGS WATER DELIVERY SYSTEMS DAVID STEFFEY CLR DISTRICT 5 NORTON, VA FINDINGS OF THE DUST

EMPHASIS TEAMS Water delivery system problems found Inadequate water pressure Undersized pump High resistance in pipe system Inadequate water volume Too small diameter water line Poor water delivery to face equipment

Hose size Piping on machine Wrong sprays FINDINGS OF THE DUST EMPHASIS TEAMS (cont.) Water related Dust Controls Specified in Ventilation Plan are Ambiguous Type of water sprays cover wide range of options can not be evaluated Specify BD-2, BD-3, BD-5 can be used Spray flow rates 0.42 gpm to 1.6 gpm

Spray type 3 Spray XX or equivalent FINDINGS OF THE DUST EMPHASIS TEAMS (cont.) Water sprays Required sprays not used Lower water flow rate

Lower water pressure Sprays are not maintained dirty, do not produce spray pattern Quickly Recognizing Problems Can Maintain Nozzle Performance, Quality and Efficiency Seven Reasons Why Nozzles Dont Perform Properly Erosion and nozzle wear Wear of the nozzle orifice and internal flow passages As a result flow is usually increased, pressure may be decreased and the

pattern may become irregular Nozzles should be checked with a pressure gage and flow meter when flow rate is 15% above published value this nozzle should be changed Corrosion Nozzle surface breaks down due to chemical action of sprayed material or environment Nozzles that are corroded should be changed Certain materials used to produce nozzles are more durable than others Choose your nozzle based on in mine conditions High temperature Not usually a factor in coal mining

Caking or bearding Build up of material on the orifice due to liquid evaporation Water quality can greatly affect this (hard water) Typically a problem with atomizing nozzles Caked nozzles should be replaced Damage Damage to the orifice can occur when improper cleaning tools are

used Meaning nails are not good for cleaning nozzles Clogging Material clogs the orifice and the spray pattern is not evenly distributed Good filtration systems can help avoid this Improper Assembly Some nozzles require careful reassembly after cleaning Simplicity of maintenance should be considered (the fewer the parts Considerations when Ensuring Water

Delivery System Meets Plan Requirements SOURCE OF THE MINE WATER Public Water storage tank Surface water pond/stream FILTRATION TO MAINTAIN A CLEAN WATER SUPPLY At source

On MMU Maintain filtration system Other Considerations Number and Type of MMUs you will use Continuous Miner Dust suppression sprays Scrubber Wethead Miner Longwall Other Water Needs Belt transfer points Regulatory requirements for fire fighting

DAVID STEFFEY CLR DISTRICT 5 NORTON, VA [email protected] Lessons Learned Dust Inspections By Brent Wolfe Health Specialist District 3 Operator Sampling

Program Sampling Unit Equipment (sampling units) not maintained as approved Flow rates not maintained at 2.0 L.P.M. Sampling head assemblies are not cleaned and inspected Pre-sampling shift checks : o Black hose used

o No voltage checks made o Pump and apparatus assembled prior to 3 hours before the start of the start of shift Sampling Procedures Respirable dust samples are not collected at required times (shifts/days) o Example : 14 days to take 5 valid samples with full production, 3 shifts a day.

Operator Sampling Program Sampling Procedures Certified persons do not know the regulatory requirements for the proper collection of respirable dust samples o A Control Filter sent in as a Regular Sample o 1 Control Sample sent in for 5 separate respirable dust samples

Improper record keeping for length of shift Maintaining sample in appropriate location: Belt DA Sample found too far away Operating sampling unit portal-to-portal Full Shift Sampling Air Quantity Air at end of curtain does not match plan o Example: Lower air quantity due to curtain found

16 off the mine floor. Air not balanced with scrubber quantity (blowing face) o Example: To much air quantity at end of line curtain (More than limits of Plan). Dust Scrubber Scrubber quantity lower than plan quantity Air quantity measurements performed incorrectly o Plugs in Pitot holes

o Not testing all Pitot holes o Holes between scrubber screen sprays and screen Dust Scrubber Ductwork dirty/plugged Screens not dried per Plan Demisters found with 1 inch thick sediment on layer filaments Sump pump not working

Roof Bolter Dust Collectors Dust box door seals not maintained - Nonapproved seals o Ex. weather stripping from home improvement store Vacuum hoses do not match approval requirements and found leaking Clean side of collector contaminated Dust box door latches not maintained

Vacuum setting does not meet approval plate Roof Bolter Dust Collectors Non-Approved Hoses being used ( electrical conduit) Electrical tape covering up holes Clean Side of system contaminated with white fine dust Latches missing; Door hinges broke; Mine sealant used to seal door. Vacuum pressures to low, Hoses not clamped onto barbed connectors.

Roof Bolter Dust Collectors Valves installed in the dust collection system. Low pressure found when valve to dust collection box turned off. Door Seals pieced together with and without approved seals. Dust Controls not being Maintained According to

Approved Ventilation Plan Water sprays Required sprays not used (1MM sprays used instead of 3/32) Lower water pressure (dirty filters, inside of hoses collapsed). Sprays not maintaineddirty, do not produce spray pattern. Dust Controls not being Maintained According to Approved Ventilation Plan

Mag Gauges not maintained Holes on adapters of Mag Gauges plugged with dirt/sediment Loose adapters on Mag Gauges CMOs do not know Plan requirements (Scrubber screen needs cleaned every 40 feet of advancement).

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