Terry Taylor called the meeting to order and welcomed everyone to Edmonton. Jim Van Emmerik read the minutes and they were approved as read. Jerry Endres provided the Treasure report. Jerry also informed the group that the printer that was lost during the Denver 2002 meeting has been reimbursed by the Renaissance hotel.
Martin Reyes announced the following future meeting sites:
Nov. 12 – 14 2003 Tucson, Arizona held at the Doubletree
May 12 – 14 2004 Rapid City, South Dakota held at the Ramkota
Nov. 17 – 19 2004 Reno, Nevada held at the Silver Legacy
May 8 – 10 2005 Calgary, Alberta held at the Sheridan
Nov. 16 – 18 2005 Denver, Colorado held at the Renaissance
Terry announced that tomorrow the group is invited on a field trip to General Electric to view a demonstration on ice blasting cleaning. Transportation is provided and lunch will be served at the General Electric facility.
As Terry had announced in Denver, Landis Bayless, is no longer employed by Texas Utilities. WMEA bylaws state that officers must be employed by a users group. At that time, Terry Taylor, moved from 1st Vice President to President. Martin Reyes moved from 2nd Vice President to 1st Vice President. Terry Taylor terminated his employment from Barrick Goldstrike in early June, 2003 . Due to the short time between Terry’s exit from Barrick and the WMEA meeting, Terry graciously volunteered to conduct the Edmonton meeting. Martin Reyes will automatically move up to President for the Tucson meeting. This left the 1st and 2nd Vice President positions open. Nominations were opened with Jed Jensen and Ed Barnett nominated. Election for these two positions will be held in Tucson. Terry stated that we are in need of steering committee members.
Terry then announced the meeting’s agenda and described the group discussion items.
Broke into 5 groups to discuss:
Problems And Solutions
Agenda items for next meeting
Welding Hazards, Mitigating the Risks – Dave Hisey, Syncrude/John Richards, Sigma Industrial Sales
New Static Drive System for Mining Excavators – Walter Koellner, Siemens
Adjourn for Lunch
Dragline GPS/Production Monitoring – Carl Hendricks, Aquila
Noise Abatement – Mark Wagener, Rod McDonald, Noise solutions/Clifford Farszer, Frazer Farquharson & Associates.
Off Highway Vehicle: Electric Drive system Interface Advancements – Alan Randolph, General Electric.
Compressed Gas Systems video – Dave Hisey, Syncrude.
Terry Taylor called the meeting to order.
Group discussion – Summary of group discussions held the previous day.
TPM-Total Productive Maintenance – Terry Taylor.
Meeting adjourned to attend General Electric Dry Ice demonstration
- Static DC Drive System With AFE
- Welding Hazards Mitigating the Risk
- Off Highway Vehicle: Electric Drive System Interface Advancements
Group 1 Discussion
Lead by Jed Jensen
- Per Dave Hisey request, discussed bonding equipment when fueling. From the group, we found that nobody in the group does it in the field not at the fueling stations. It was mentioned by several that they have a bonding means for off loading tankers and blasting trucks.
- Garry Farnsworth: mentioned an incident at their mine when there was an explosion in a blast hole. They had drilled the hole and they used a plastic liner in the hole to put the explosives down hole. While the full report is not yet available, preliminary reports point to a methane ignition in the hole with the ignition source being static caused by the blasting materials sliding on the plastic liner of the hole. It was a hole in overburden, but had been drilled to the coal. Others in the group also mentioned that there had been methane ignitions on their properties at various locations, often in dewatering fields.
- Tony Pasula: mentioned that he had been on a job at a hydro station and they saw an electrician working on the top of a six-foot ladder. Not only was he on the top, but he was also straddling the top with on foot on a rung and the other on a brace on the opposite side.
- Dave Hisey: mentioned that at Syncrude they have been holding an annual safety symposium. This year they had a couple of fighter pilots as motivational speakers. The speakers talked of the need for safety in all jobs. One of the main topics this year was a doctor speaking on alcohol and drugs in the work place. The total symposium lasts for about three days. They have all of the mine leadership attend for ½ day sessions. In turn they are too take what they learn back to the workforce. Syncrude is doing this in an attempt to make their mine a zero injury work place.
- Homero Perez: Mentioned an article on fall protection. According to the articles, after a fall, suspension in an upright position can often be fatal. Plans need to be made for rapid rescue after any fall. That led to a discussion of the need for proper tie-off points on equipment.
- Finally, there was a discussion of noise and occupational hearing loss. We discussed differing concerns with noise, both internal and external to mining equipment.
Problems / Solutions
- Duane Kalmbach of B&B Electric Motor talked about a new test procedure that they have developed. It is an Inductions Rotor Bar Test. The rotor must be tested out of the machine and they use a high current and low voltage to do the test. They say the test shows great promise in diagnosing potential rotor bar failures.
Gary Mostyn of Americable mentioned that they are adding a 3M reflective tape, which is pressed into the jacket to help with cable visibility at night. They do have some cable with this tape currently under test at a mine.
- Gary Mostyn, Americable: 1) He had attend a mining show where the Operations Manager of the Que Creek Mine gave a presentation. He mentioned that to be a very interesting presentation. 2) He mentioned that there is a company in California who had done presentations on ‘Virtual Reality Training’ for shovels, draglines & longwall operations.
- Rick Scherer: suggested that we again have presentations for MSHA or and MSHA panel
- Gary Mostyn: Could have a representative from the National Mining Association
- Rich Scherer: Suggested that perhaps Jon Vendela do a presentation on the softstart upgrade he is planning for his dragline.
- Tony Pasula: Mentioned that it has been a long time since there had been a presentation on Basic Motor Maintenance and T/S helps on motors.
- Rich Scherer: Would be good to have a presentation on Predictive Maintenance tools, equipment and successes. Garry Farnsworth mentioned a company called Design Maintenance and one who might be able to help with that.
- Rich Scherer: Wanted to hear a presentation on the latest of Sync Motor Protection.
Group 2 Discussion
Lead by Martin Reyes
- MARTIN BGMI: TALKED ABOUT BGMI MINE DIVISION REACHING 3 MILLION MANHOURS NO LTA IN MAY31 2003. ALSO TALKED ABOUT A NEAR MISS WITH A VENDOR WHO WAS UNLOADING A TRUCK WITH A FORKLIFT. HE SET THE PARK BRAKE GOT OFF THE MACHINE AND GOT IN BETWEEN THE TRUCK AND THE FORKLIFT. THE PARK BRAKE DIDN’T HOLD AND PIN HIM AGAINST THE TRUCK. FORTUNATELY HE ONLY SUFFERED A BROKEN ANKLE.
- DAVE DENSE COAL VALLEY COAL: TALKED ABOUT HOW ALBERTA IS REALLY PRESSING ON SAFETY. THIS IS TO REDUCE COST FOR WCB. ACCIDENT REDUCTION COURSES ARE BEING OFFERED THROUGH LUSCAR.
- JERRY RUSH OF P&H: TALKED ABOUT ALBERTA’S STANCE ON STRESSING SAFETY ON THE JOB. THOSE COMPANIES WHO DO A LOT OF EDUCATION FOR THEIR EMPLOYEE’S SE A COST REDUCTION WITH WCB.
- POWERED RIVER BASIN: TALKED ABOUT HOW VENDORS HAVE TO GO THROUGH SAFETY ORIENTATION & DRIVING TEST FOR THE MINE SITE. THEY ALSO DISCUSSED AN INCIDENT WITH A 240TON TRUCK THAT RAN OUT OF FUEL. THE OPERATOR STARTED DOWN THE LATTER WHEN THE TRUCK STARTED ROLLING BACKWARDS. APPARENTLY THE BRAKES DIDN’T SET PROPERLY. FORTUNATELY THE OPERATOR DID NOT GET HURT SERIOUSLY AND NO MAJOR DAMAGE DONE TO THE TRUCK.
- JOHN FROM KENNICOTT: TALKED ABOUT A VIRTUE REALITY TRAINER THAT KENNICOTT PURCHASED. IT IS FOR TRAINING OPERATORS ON TRUCKS AND SHOVELS. IT IS DESIGN TO HELP DEVELOP BETTER RESPONSE IN EMERGENCY SITUATIONS. THEY FEEL THIS WILL BE A GREAT TOOL TO REDUCE ACCIDENTS.
- DONNIE COCHERMAN: DISCUSSED SAFETY OBSERVATIONS THAT ARE BEING DONE BY EMPLOYEE’S BY EACH OTHER AND HOW WELL THAT’S BEEN GOING.
- DAVE DENSE COAL VALLEY COAL: TALKED ABOUT JOB PLANS FOR EMPLOYEES. THESE ARE TAKEN IN THE MORNING, LIST OF MATERIALS, TOOLS AND HAZARDS AREA LISTED WITH EACH JOB PLAN.
- JOHN VENDELLA OF KENNICOTT: TALKED ABOUT THEIR PROJECT ON REDUCING THE AMOUNT OF CABLE HANDLING FOR DRAGLINE CABLE. LOOKING AT DIFFERENT TYPE OF CONNECTORS, J-BOXES ETC.
- DAVE DENSE: TALKED ABOUT HOW A REVISED CABLE HANDLING PROCEDURE AT COAL VALLEY COAL HAS SHOWN REDUCTION IN CABLE DAMAGE AND INCIDENTS.
Problems and Solutions
- PRESENTATION FOR CABLE INFORMATION ON DIFFERENT TYPES OF CONNECTORS, J-BOXES AND CABLE. JOHN VENDELLA MAY BE ABLE TO DO ONE AFTER THEY COMPLETED THEIR PROJECT AND WORKS OUT.
- GROUND FAULT AND GROUND CHECK SYSTEMS
JEFF GLENNEY OF STARTCO MAY BE ABLE TO DO A PRESENTATION
Future Meeting Locations
Group 3 Discussion
Lead by Jim Van Emmerik
- In regards to grounding of haul truck during fueling, two mines said that they use no grounds at all. Bob Ford of Coteau said that when fueling from their service truck, the service truck is bonded to the vehicle being fueled by a cable with a welding clamp.
- Paul Doyle of Barrick Goldstrike told us about Barricks’ safety incentives:
- A pool of money exists, each incident deducts from the pool, and any late reporting results in a severe reduction. At years end, the money left in the pool is divided amongst the employees.
- Additionally, if the quarterly medical reportable goal is met (currently under 4), a prize is drawn for. Recently a big screen television was given away. This quarter the prize is a trip and $1,000 in cash.
- Walter Koellner of Siemens mentioned of a program that has an elaborate formula for safety incentives.
- Antelope Coal has achieved 400 plus days without a lost time accident. This includes contractors as well.
- Bob Gaulton of Syncrude asked what others are doing regarding electricians working alone vs. working in pairs. While doing high voltage switching Paul Doyle of Barrick Goldstrike said that they work in pairs. Antelope Coal electricians could be alone.
- Bob Ford of Coteau described what they use for an incentive system to bring forth new ideas. They call it CIP, Coteau Improvement Process. To submit an idea, a form is filled out and then reviewed by a review board. If the idea is implemented, points are awarded and goods can be purchased from the company store. Additionally, they have incorporated a scratch card with values of 5 to 50 points. These are given to employees that are observed demonstrating safe behavior. The review board also follows up to insure that the approved suggestion has been implemented.
- Walter Koellner of Siemens mentioned that remote diagnostics are continuing to improve machine optimization. Additionally, Walter told us of a gearless dragline that is on the drawing board. Walter also spoke of haul truck testing that is being conducted in Australia to reduce the noise level on inverter driven motors by 3 or 4 decibels. Changing the pulse patterns does this.
- Bob Gaulton of Syncrude spoke of a system where the technicians carry a laptop with them in their service vehicle. When they are called to a piece of equipment requiring service, the technicians write the work order then and there. They then input their own information as to what they did and no one can change that data. Additionally, they have a remote diagnostic system on a couple of haul trucks. The dispatcher monitors these vehicles remotely and when a fault arises, the dispatcher can, in a lot of instances, tell the technician what the problem is before they arrive at the truck.
- Gearless dragline-Walter Koellner.
- Invite MSHA to discuss their view on testing/calibration of mechanical vs. solid-state relays.
- Status of development of autonomous trucks
Future Meeting Locations
Group 4 Discussion
Lead by Dennis Isaacs
- Jerome Ziegler – Coteau Mine – MSHA wanted them to check and record low voltage circuit breakers. The mine wanted to know what procedures to take in order to do this. MSHA does not tell you how they want them checked – whether to load test them or turn them off and on.
- Jerome Ziegler – Coteau Mine – Coteau mine gives gifts for each person that goes a certain amount of time without an accident. Recently that was a smoke detector.
- Jerome Ziegler – Coteau Mine – Their mine is starting to focus on close calls and near misses, they report small incidents and are trying to heighten safety awareness.
- Daniel Adams – Kennecott Mine – Their mine is focusing on the small problems that could lead to big problems – recently they installed a mirror at the scale house, it was not needed but a couple of times a year but they felt like it could cause a big problem some day.
- David Barrett – Drives and Control Services – Suggested that anyone that was still using Oil Circuit Breakers that they should look into replacing them. They are becoming obsolete and the dangers of blowing up with the hot oil in them could be potentially serious. They had recently replaced some with vacuum starters at one of the mines they service.
- Dennis Isaacs – Westmoreland Coal – Jewett Mine – Gives each employee a $300 bonus if the mine completes one year without a lost time accident, recently we had a bad rash of lost time accidents and our mine manager said he would give each employee one day pay if we could go one month without a lost time accident. He thought that would turn things around and get us on the right track again.
- Jeff Glenney – Startco Engineering – they have upgraded their design on the Startco ground monitor termination block from a screw termination to having the leads come out of the device so the customer can crimp or solder the connection.
- Dean Jeffrey – Luscar – They are soon starting a $14.5 million overhaul on a 1360 BE Dragline – Replacing bull gears, boom work, new motor control centers that would barely fit in the existing space, digital generator field drives and lots of other upgrades and repairs. This is scheduled to be a 90 day outage.
- David Barrett – Drives and Control Services – their company is building pre-wired e-houses to be installed on the draglines during an outage. These e-houses have the PLC’s, digital drives, contactors, relays, etc. installed with terminal strips to connect the existing wiring from the machine. They just set the e-house on back of the machine and hook it up.
- Mark Johnston – Bucyrus – They are logging on to a central PLC and are able to remotely change drive parameters and fine tune machines from their office, not just monitor the actions of the machine but to actually change drive parameters etc. They have this installed on a 495 shovel. They are also installing another PLC on the machine to record and monitor machine functions. The PLC will record data for several weeks and they are able to search back to find the position the machine (such as the bucket position etc.) and what caused the problem when the trip occurred.
- Daniel Adams – Kennecott Mine – They are focusing on better installations of new equipment, making sure they are installed up to code, using the right parts and doing the job right the first time. Their mine is also trying to combine PM processes to be more integrated with other PM’s for the same machine and changing the frequency of some of the things being inspected such as inspecting an item that they never have any problems with every year instead of every three months.
- We also discussed boom lowering procedures. MSHA told us at our mine not to jumper the ground monitor system while lowering the boom unless we had an alternate method that was approved by the secretary. Apparently that was one of MSHA’s topics discussed recently at their Denver meetings.
- There was a question to all groups about bonding the lube truck while refueling. There were two mines in our group that did bond the fuel truck while refueling. One used a clamp to clamp to the truck, the other used a pin and sleeve type connector that would pull apart if they forgot to disconnect it before driving off.
- Try to get someone from MSHA to explain the discrepancies between the inspectors interpretations.
Group 5 Discussion
- Spent most of the session discussing issues related to noise control. Noise sources primarily, machinery in excavating equipment, off-highway rolling stock and air arcing.
- Air arcing affects both the person doing the work and individuals in the vicinity.
- Noise from this source is directional to some extent.
- Comment that experiments are being conducted to measure the effect of changing tips to reduce noise from this procedure. Since the noise source is the air stream, tip design plays a part in the sound intensity of the process.
- Low frequency sound not attenuated as much as high frequency so it travels farther. A 10 db reduction in sound level constitutes a 50 % reduction Ear protection most effective at higher frequencies, but filtering of low frequencies not as pronounced. Noise reduction involves more than just ear protection. High sound levels can be transmitted through the body skeletal structure; appropriate footwear can offer some reduction in sound transmitted in this manner.
- Sound absorbing material, when installed in mine, needs to be waterproof and fire proof.
- Comment that companies consider hearing test as part of a pre-employment physical. Employee hearing problems can be identified prior to subjecting person to environment that might aggravate condition.
- Methods of communicating information to employees, especially at the craft level.
- Presentation on trail cable spec’s being developed by Syncrude.
Future Meeting Locations
- Murray Duncan of Amercable looking for source to do electrical drawings.