# Presentation: 770222

## Remote Control

- Hazard Awareness

- Remote Control Outreach

## Victim Location With Respect to the Machine

- 29 fatalities since 1984
- 12 fatalities since 2000 (41%)
- 3 fatalities in 2004

- Remote Control Outreach

**Notes:**
There have been 29 remote control continuous miner fatalities from 1984 through 2004.  However, 12 of these fatalities have occurred since 2000.  MSHA has prepared this presentation as a training tool to educate the mining industry about the history of these types of fatalities so that we can identify problem areas on which to focus to reduce and eliminate these types of accidents.

Remote control continuous miner (RCCM) fatalities usually result from crushing injuries to a victim who is positioned within the turning radius of the continuous miner.  As is apparent in this diagram, the locations of the victims are clustered at the pinch points of the continuous miner.

## Victims Operating the Remote

*Victims Operating the Remote*

- Of the 29 fatalities, **72%** of victims were operating the remote at the time of the accident.

- Not operating the remote

- Maintenance  activity

- Victim location

- X

- Operating the remote

- Legend

**A moving RCCM collided with**
**another at an intersection,**
**causing the stationary RCCM**
**to pivot and crush the other Op **

- Remote Control Outreach

**Notes:**
The majority of the RCCM fatality victims were crushed by the machine while they were operating the remote.  Like other miners, RCCM operators have lots of responsibilities and must focus their attention on many things at once.  MSHA challenges you to consider your own safety as a top priority.

## Equipment Involved in the Fatality

| Miner Make | Miner  Model | Qty | Total |
| --- | --- | --- | --- |

| Joy | 12CM | 9 | 19 |
| --- | --- | --- | --- |
|  | 14CM | 9 |  |
|  | 12HM | 1 |  |

| Simmons-Rand | 500 | 2 | 3 |
| --- | --- | --- | --- |
|  | 525 | 1 |  |

| Eimco
(one Marietta 2460-1) | 2810 | 1 | 3 |
| --- | --- | --- | --- |
|  | 2460 | 2 |  |

| Jeffrey | 1028HP | 1 | 4 |
| --- | --- | --- | --- |
|  | 101MC | 1 |  |
|  | 1036 | 2 |  |

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**Notes:**
Several makes and models of continuous miners have been involved in RCCM fatalities.
Seventeen of the mines where RCCM fatalities occurred used shuttle car haulage; 5 used ram cars or unahaulers; 3 used mobile bridge conveyors; 3 used shuttle car and ram car haulage; and 1 mine used scoop haulage.

## Equipment Involved in the Fatality

| Remote Make | Remote  Model | Qty | Total |
| --- | --- | --- | --- |

| Matric | Plastic Station | 7 | 13 |
| --- | --- | --- | --- |
|  | TX2 | 1 |  |
|  | TX3 | 5 |  |

| Not Reported | Radio | 9 | 11 |
| --- | --- | --- | --- |
|  | Umbilical | 2 |  |

| Moog | 129
unknown | 3
1 | 4 |
| --- | --- | --- | --- |

| Marietta | Pendant unit (umbilical) for drum miner | 1 | 1 |
| --- | --- | --- | --- |

- Remote Control Outreach

**Notes:**
The make and model of the remote involved in the RCCM fatalities was not always included in the fatal accident report.  
Although the current trend is that a continuous miner can be adapted to work with any make of remote, historically a continuous miner could only be operated with a specific remote.

## Remote Control CM Fatal Accident History

*Remote Control CM **Fatal Accident History*

- Remote Control Outreach

**Notes:**
Again, 40% of the RCCM fatalities have occurred since 2000.
The MNM fatality occurred at a trona mine with an integrated miner/bolter.

## Remote Control Fatalitiesvs. All Fatalities

*Remote Control Fatalities**vs. All Fatalities*

**The trend line for RC fatalities is upward which is **
**contrary to the overall fatality trend**

- Remote Control Outreach

**Notes:**
The number of all fatalities, in the metal/nonmetal and coal industries, has been declining in recent years, but the number of RCCM fatalities is increasing.

## Remote Miner Population

*Remote Miner Population*

|  | Continuous Miner MMUs |  |  |  |  |  |
| --- | --- | --- | --- | --- | --- | --- |
|  | Without Remote Control |  | With Remote Control |  | Total |  |
| District | 2002 | 2005 | 2002 | 2005 | 2002 | 2005 |
| 1 | 2 | 2 | 0 | 0 | 2 | 2 |
| 2 | 4 | 1 | 33 | 57 | 37 | 58 |
| 3 | 10 | 2 | 32 | 58 | 42 | 60 |
| 4 | 13 | 22 | 105 | 157 | 118 | 179 |
| 5 | 13 | 2 | 82 | 83 | 95 | 85 |
| 6 | 8 | 6 | 76 | 112 | 84 | 118 |
| 7 | 3 | 3 | 80 | 99 | 83 | 102 |
| 8 | 0 | 0 | 47 | 60 | 47 | 60 |
| 9 | 0 | 0 | 17 | 40 | 17 | 40 |
| 10 | 0 | 4 | 21 | 27 | 21 | 31 |
| 11 | 0 | 0 | 16 | 21 | 16 | 21 |
| Total | 53 9.4% | 426% | 50990.6% | 71494% | 562100% | 756100% |

- Remote Control Outreach

**Notes:**
30 CFR does not require mine operators to report the number of active continuous mining machines.  However, mechanized mining units (MMUs) are required to be reported for Part 70 dust sampling purposes.  MSHA gathered the number of remote control continuous miners from the MMU database and a survey of the District Health Specialists.
This chart indicates the numbers of continuous ripper MMUs only; it does not include shearer MMUs, cutting machine MMUs, conventional methods, etc.
Some MMUs have more than one continuous miner associated with them (i.e. supersections), which is why the number of continuous miners in a District may be higher than the number of MMUs.
All the bituminous coal Districts experienced an increase in the number of remote control MMUs between December 2002 and April 2005.
Among the four underground trona mine operators in the Rocky Mountain District, 12 of 17 continuous miners in use are remote controlled.

## Remote Miner Population

*Remote Miner Population*

**Since 2003 there is an increase of 40%**

- Remote Control Outreach

**Notes:**
The number of active remote control continuous miners has increased by 40% from December 2002 to April 2005.
As is apparent in the chart, all of the Districts have seen an increase in the number of remote control continuous miners in use, even if the number of overall MMUs in the District declined (as it did in District 5 – Virginia).

## Remote Control CM Facts

- The use of remote control continuous miners is expected to rise in the future.
**72%** of the victims were operating the remote at the time of the fatality.
- Remote fatalities are on an upward trend.
- We must work together to reverse this trend.

- Remote Control Outreach

## Fatalities by Shift

**62%**** occurred during an off-shift,****contrary to a majority of workers on the Day Shift.**

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**Notes:**
Exposure to RCCM accidents should be greatest on the day shift because many mines perform maintenance on off-shifts, some mines run additional sections on the day shift, and some mines only produce on one shift a day (usually the day shift).

## Fatalities by Day of the Week1984-1999

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**Notes:**
This chart shows the day of the week of the RCCM fatality.  However, this represents the more traditional work week (Monday to Friday) that was common during this time (1984 through 1999).
These numbers indicate for this type of work week, safety meetings and other awareness activities could be focused on that the beginning and ending of the traditional work week.

## Fatalities by Day of the Week2000-2004

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**Notes:**
These numbers reveal a more even distribution of RCCM fatalities as more operators began working 7 days/week.
For this type of work week, safety meetings and other awareness activities could be focused on Tuesdays and Fridays.
A review of total coal mine fatalities that occurred between 2000 and 2004 indicates that Wednesday was the most frequent day of the week for a fatality to occur.  19% of coal fatalities occurred on Wednesday; Tuesday was second with 18%.
A review of total metal/nonmetal fatalities that occurred between 2000 and 2004 indicates that Monday was the most frequent day of the week for a fatality to occur.  25% of metal/nonmetal fatalities occurred on Monday; Tuesday was second with 19%.
Although the distribution of fatal accidents between Monday and Friday for both coal and metal/nonmetal mines was evenly distributed for the 2000 – 2004 period, the percentages of accidents occurring on Saturday and Sunday was slightly lower.

## Fatalities by Total Mining Experience

*Fatalities by Total Mining Experience*

- Experience rounded to the nearest year

- Fatalities are happening to experienced miners.
**79%** of the victims had greater than 10 years of mining experience.

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**Notes:**
Please note that total mining experience is rounded to the nearest year.
A review of coal mine fatalities that occurred between 2000 and 2004 indicates that 79% of victims had more than 10 years of mining experience. The mining experience of the victims in RCCM fatalities is comparable to the mining experience of victims in all coal fatalities, in that fatalities are happening to more experienced miners.
A review of metal/nonmetal mine fatalities that occurred between 2000 and 2004 indicates that 48% of victims had more than 10 years of mining experience.

## Fatalities by Experienceat the Mine where the Fatality Occurred

*Fatalities by Experience**at the Mine where the Fatality Occurred*

- Experience rounded to the nearest year

**65%**** of the victims had less than 2 years ****experience at the mine**

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**Notes:**
Please note that experience at the mine is rounded to the nearest year.
One possible reason for this trend is that an experienced miner with little or no equipment operating experience may begin operating equipment upon employment at a new mine (or be assigned a job at a new mine that he has no experience in).
Another possibility is that a newly employed experienced miner is operating different equipment (make or model) at the new mine than what he is familiar with.
A review of coal and metal/nonmetal fatalities between 2000 and 2004 indicates that 59% and 54% of victims, respectively, had less than 2 years of experience at the mine.
This indicates that comprehensive training is important for both inexperienced and experienced miners when beginning work at a new Mine.

## Fatalities by Job Classification

*Fatalities by Job Classification*

**76%** of victims were Miner Operators or Maintenance
- Foremen should lead by example: Stay out of the ***“Red Zone”*** and do not become a fatality statistic.

- Remote Control Outreach

**Notes:**
Maintenance personnel includes mechanics, electricians, mechanic/electrician helpers, and trainees.
Two of the maintenance personnel were working as continuous miner helpers at the time of the fatalities.
One of the continuous miner operators was performing maintenance (changing bits) at the time of the fatality.
One of the foremen was moving the miner on a maintenance shift, another was trimming bottom, and the third was moving the second miner into position for the next cut.
The miner operator was unaware that the roof bolter operator exited the on-board bolter station.  The roof bolter operator was pinned between the boom and the rib.
Maintenance personnel accounted for 22% of coal mine fatalities between 2000 and 2004, while foremen accounted for 13%.
Maintenance personnel accounted for 20% of metal/nonmetal fatalities between 2000 and 2004, while foremen accounted for 17%.

## Fatalities per Activity

*Fatalities per Activity*

**Fatalities are occurring during the regular mining cycle.  **
**These activities must be managed with good safety practices.**

- Remote Control Outreach

**Notes:**
Most of the RCCM fatalities are occurring as personnel perform basic, repetitive functions of the mining cycle.
Place changing fatalities can be prevented by staying out of the turning radius of the energized miner.  Taking short cuts means taking risks when working around remote control continuous miners.
All employees should be aware of their position with respect to an energized remote control miner, and remember that this includes the area above and below the miner as well as the sides.

## Fatalities per Mining Seam Height

*Fatalities per Mining Seam Height*

**Fatalities are occurring regardless of the seam or bed height**

- Remote Control Outreach

**Notes:**
The heights depicted on the chart are the heights by mine operators to MSHA on the 2000-122 Mine Status Data form .
The heights have been rounded to the nearest foot.

## Remote Control Best Practices

- Establish safe operating procedures for remote control continuous mining machine operations, which include:
- Tramming
- Cable handling
- Maintenance
- Setting over
- These procedures must be practical and useful.
- Consult with the equipment operator when establishing the procedures.
- All miners, regardless of experience or job classification, must be trained in these procedures.
- All miners must enforce these procedures.

- Remote Control Outreach

**Notes:**
Mine operators must establish safe operating procedures for remote control continuous mining operations.  Everyone must be trained in these procedures.
Miners should not only follow these procedures themselves, but point out to a coworker if he positions himself in a pinch point or otherwise puts himself at risk.

## RED ZONES ARE NO ZONES

**RED ZONES ARE NO ZONES**

- FOR
- MINING WITH REMOTE CONTROL CONTINUOUS MINERS

**NOTE:**
**THESE DRAWINGS DO NOT SUPERCEDE**
**ANY STATE OR FEDERAL REQUIREMENT**

**Developed through a cooperative effort between MSHA’s District 5 Office, the Virginia DMME, and local mining companies**

- http://www.msha.gov/Alerts/20040407REDZONE2.pdf

- Remote Control Outreach

## RED ZONES ARE NO ZONES

**RED ZONES ARE NO ZONES**

- FOR
- MINING WITH REMOTE CONTROL CONTINUOUS MINERS

**NOTE:**
**THESE DRAWINGS DO NOT SUPERCEDE**
**ANY STATE OR FEDERAL REQUIREMENT**

**Developed through a cooperative effort between MSHA’s District 5 Office, the Virginia DMME, and local mining companies**

- http://www.msha.gov/Alerts/20040407REDZONE2.pdf

- Remote Control Outreach

## RED ZONES ARE NO ZONES

**RED ZONES ARE NO ZONES**

- FOR
- MINING WITH REMOTE CONTROL CONTINUOUS MINERS

**NOTE:**
**THESE DRAWINGS DO NOT SUPERCEDE**
**ANY STATE OR FEDERAL REQUIREMENT**

**Developed through a cooperative effort between MSHA’s District 5 Office, the Virginia DMME, and local mining companies**

- http://www.msha.gov/Alerts/20040407REDZONE2.pdf

- Remote Control Outreach

## RED ZONES ARE NO ZONES

**Remember that the *****“Red Zone”***** extends above the Machine.**
**DO NOT get crushed between the machine and the roof.**

**of this *****Red Zone******!***

**KEEP OUT**

- Remote Control Outreach

**Notes:**
Many fatal and non-fatal RCCM accidents have occurred because miners positioned themselves over the continuous miner or positioned their foot under the gathering pan.  The Red Zone includes the area above and below the miner because it may tilt upwards quickly and unexpectedly as it trams over uneven bottom.

## Remote Control Task Training

**MSHA is working with companies to develop *****Job Task Analysis***** related to the operation of ****remote control continuous miners**

**Adequate task training should be performed****to assure safe operation of equipment**

**mine specific**

**equipment specific**

**developed by miners**

**creates effective efficient data****for training design**

**IMPROVES**

**SAFETY**

**COMMUNICATION**

**PRODUCTIVITY**

**SAFETY**

**Training required by law**

**Promotes good employee morale**

**Saves Money**

**Saves Lives**

**TRAINING**

_**www.msha.gov/interactivetraining/tasktraining/index.html**_

- Training Improves Safety** **

- Use this online tool to developadaptable training that will improve your mines’production, safety, communication, and maintenance.

- Remote Control Outreach

**Notes:**
MSHA encourages miners, managers, and safety and health professionals to use the information and tools available on the MSHA website.  In particular, MSHA provides an online tool to develop adaptable training.

## Remote Control Best Practices

**Tramming While Positioned Within The Turning Radius Of The Remote Control Continuous Miner Can Be Fatal**

**Tram the continuous mining machine from a safe location ****to avoid pinch points**

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**Notes:**
The single most important factor in the prevention of remote controlled continuous miner crushing accidents is the location of personnel outside of the machine’s turning radius.  This includes the area above and below the miner.
Never position yourself in the turning radius of the remote control continuous mining machine while it is being repositioned or trammed for a place change. 
Never enter the "red zone" unless the machine and remote control unit are de-energized according to established safe work practices.

## Remote Control Best Practices

**The Middle of the Remote Control Continuous Miner****Is Not A Safe Place to Tram **

**MSHA challenges you to look closely at the operation of the remote control continuous miner**** the next time you are on the section**

- The middle of the remote control continuous miner (pivot point) is not a safe place from which to reposition or tram the machine during a place change.
- The pivot point moves as the machine moves and may cause you to be in a position to be crushed if the miner suddenly turns.

- Remote Control Outreach

**Notes:**
Never operate the continuous miner when anyone is in the Red Zone.
Although some roof control plans prohibit tramming the continuous miner from within the turning radius of the machine, it is important for You to always remember to Stay Out of the Red Zone! 

## Remote Control Best Practices

**Tramming While Positioned Within The Turning Radius Of The Remote Control Continuous Miner Can Be Fatal**

**The pump motor should be de-energized, and all machine motion stopped, when the trailing cable or water line has to be repositioned in close proximity to the machine**

- Remote Control Outreach

**Notes:**
When handling the cable within the turning radius of the remote control continuous miner, de-energize the machine and remote control unit according to established safe work practices. Many fatal and near miss accidents have occurred because the cap lamp cord, a tool, or a body part accidentally pushed a tram lever. Ensure that you and your co-workers always work safely. DO NOT RISK entering the remote control continuous miner's turning radius to handle the cable unless the machine and remote control unit are de-energized according to established safe work practices. 

## Remote Control Best Practices

**Turning a Remote Control Continuous Miner**

- ALWAYS expect the remote control to move the crawlers (CATS) in the same direction regardless of the direction you are facing.
- DO NOT become disoriented because your position changes.  The operation of the remote control does not change if you are at the rear, facing forward or in the front, backing out.

- Remote Control Outreach

**Notes:**
Since the operator of a remote control machine is mobile, it can be easy for one to issue an incorrect machine command for an intended movement.  While his relative position with respect to the machine changes, an operator can become confused as to which switch movement is correct for an intended machine movement.  For example, if an operator is at the rear of the machine, and facing the machine, moving a tram forward switch away from the operator results in a forward movement of the tram crawlers, and the machine moves away from the operator.  However, if an operator is at the front of the machine, and still facing the machine, moving a tram forward switch away from the operator again results in a forward movement of the machine, but this time the machine moves toward the operator.  

## Remote Control Best Practices

**Keep Your Mind On Your Work**

- Communicate with co-workers and maintain clear visibility with all personnel in the vicinity of moving equipment.
- De-energize the machine and remote control unit according to established safe work practices before entering the ***”RED ZONE”***.

- Remote Control Outreach

**Notes:**
Operators of remote controlled continuous mining machines have many things to do and think about. Safety is one of many concerns for a continuous mining machine operator. Never reposition the mining machine or tram it for a place change if you are positioned in the machine's turning radius. 

## Remote Control Best Practices

**When Radio Signal is Lost****Don't Approach Remote Control Continuous Miners**

- If the remote control continuous miner is not following the commands of the radio remote control, DO NOT get within the machine's turning radius to get closer to the machine's antenna.
- Assume the machine or remote control unit has malfunctioned and proceed according to established company policies for maintenance and trouble shooting of the radio remote control equipment.

- Remote Control Outreach

**Notes:**
It is a common tendency to believe the radio control signal is not making it to the machine's antenna when the machine is not following the radio remote control commands. Check that the Remote Control Unit is powered up by the cap lamp battery, and then try the control command again. 

## Remote Control Best Practices

- Follow the established Standard Operating Procedure while tramming the remote controlled continuous miner.
- When moving continuous mining machines around corners, or in other instances where the left and right traction drives are operated independently, low tram speed should be used.
- Ensure that continuous mining machine operators lower the conveyor boom and ripper head, as far as possible, prior to moving the machine.

- Remote Control Outreach

**Notes:**
In addition to helping to increase visibility, lowering the conveyor boom and ripper head may help to slow a sudden movement of the machine which could contact a miner or miner’s helper.  Also, lowering the conveyor boom may reduce or eliminate the pinch point above the boom.

## Remote Control Best Practices

- All personnel should verify their proposed route of travel is clear when tramming continuous miners into position.
- All power circuits and electrical equipment shall be de-energized before any work is done on such circuits and equipment.
- All areas where persons are required to work or travel should be kept free of tripping and stumbling hazards.

- Remote Control Outreach

## Available Proximity Protection Systems

**Geosteering Tramguard**
- Display enclosure, personal alarm device, and field generator
- Contact:  Dwayne Towery, Gamma Services International, Inc., Clay, KY, (270) 635-0482,email: _[dwayne@gsimining.com](mailto:dwayne@gsimining.com)_.

- Remote Control Outreach

## Available Proximity Protection Systems

**Nautilus International Buddy System**
- Contact:  Jason Hart, Nautilus International Control & Engineering, Ltd, 6866 Russell Ave., Burnaby, BC, Canada V5J 4R9, (604) 430-8316, email: _[jason.hart@nautilus-intl.com](mailto:Jason.hart@nautilus-intl.com)_, web: _[www.nautilus-intl.com](http://www.nautilus-intl.com/)_.

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## Triangle of Success

*Triangle of Success*

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**Notes:**
MSHA uses the tools provided in the 1977 Act to help create a culture of prevention in the mining industry.  These tools--enforcement, education and training, and technical assistance--are known as the “Triangle of Success”.

## Our Ultimate Measure of Success

*Our Ultimate Measure of Success*

- Every Shift

- Every Day .........

- Remote Control Outreach

**Notes:**
But the ultimate measure of success in the mining industry is to return a miner safely home at the end of every day and every shift.

## Data Sources

- The MSHA fatal accident reports_http://www.msha.gov/fatals/fab.htm__ _
- Remote control fatal accident analysis report of victim’s physical location with respect to the mining machine_http://www.msha.gov/webcasts/Coal2005/__Fatal Accident Summary.pdf__ _
- The 7000-1 accident forms submitted by operators

- Data presented in this presentation was gathered from:

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## What do you need from MSHA?

- Share your recommendations and ideas with the rest of the mining industry...
- 	E-mail MSHA at:
- _thomas.charles@dol.gov_
-  or
- _chirdon.david@dol.gov_

- Remote Control Outreach

**Notes:**
MSHA needs feedback to continually respond to the changes in the mining industry.  If you would like more information about remote control safety, or you have specific tips or remedies, use these contacts provided on the screen.