UNITED STATES
DEPARTMENT OF LABOR
MINE SAFETY AND HEALTH ADMINISTRATION

District 6

ACCIDENT INVESTIGATION REPORT
(Surface Coal Mine)

FATAL MACHINERY ACCIDENT

LETCHER CO. #5 (I.D. NO. 15-17721)
GOLDENS CREEK ENTERPRISES, INC.
JENKINS, LETCHER COUNTY, KENTUCKY

FEBRUARY 8, 1996

by
Jimmy Brown
Coal Mine Safety and Health Inspector

Garey L.Farmer
Coal Mine Safety and Health Inspector


Originating Office - Mine Safety and Health Administration
100 Ratliff Creek Road, Pikeville, Kentucky 41501
Carl E. Boone, District Manager

ABSTRACT

On Thursday, February 8, 1996, at approximately 8:25 a.m., a machinery accident occurred at Goldens Creek Enterprises, Inc.'s, Letcher Co. #5 Mine, resulting in fatal injuries to John Raymond Greene, swingman/auger helper. Greene had 20 years of mining experience, with 16 years of experience as a swingman/auger helper. Greene was standing in the crossover conveyor located in the belly pan of the Salem 1500-B coal auger while cutting bits were being changed. The side engine, started which controls the auger's hydraulic system, was started. The side engine is also used to start the carriage engine, which rotates the auger cutting head. When the side engine started, the crossover conveyor was set in motion. The victim was pulled across the belly pan into the throat of the discharge conveyor, resulting in fatal injuries. The accident occurred as a result of the auger being started without all persons being in the clear and moving parts not being blocked against motion while maintenance work was being performed.

GENERAL INFORMATION

Letcher Co. #5 is a surface coal mine located on the Premier Elkhorn mining complex off U.S. Route 23, near Jenkins, Letcher County, Kentucky. The principal company officers are Tommy G. Gambrel, president, Tommy Stewart, vice-president, and David A. Faulkner, superintendent.

The mine utilizes the auger method of mining, extracting coal from the Elkhorn #3 Rider seam, which averages 20 inches in thickness. Mining is performed with a Model S-1500-B, single- head coal auger, manufactured in 1984 by Salem Tool, Inc. This auger is equipped with two diesel engines. The first, referred to as the side engine, powers the auger's hydraulic system. All conveyors, jacks, skids, hoists and the starter for the carriage engine are powered by this system. The second, referred to as the main or carriage engine, powers the auger cutting head and connecting auger flights.

The mine employs 5 miners and normally operates two shifts per day, six days per week. Average daily coal production is 150 tons.

The coal is stockpiled, then hauled by trucks owned and operated by independent contractors to a coal processing and loading facility.

The last regular health and safety inspection conducted by the Mine Safety and Health Administration was completed on December 13, 1995.

DESCRIPTION OF THE ACCIDENT

On Thursday, February 8, 1996, the day- shift crew began work at 7:00 a.m. Augering activities progressed until approximately 8:15 a.m., when the first auger cycle was completed. Prior to starting a new cycle, the auger was shut down for refueling.

John R. Greene, swingman/auger helper, and James E. Allen, foreman/auger operator, checked the cutting bits on the auger head during this time and decided a bit change was necessary. Green and Allen changed the bits that were accessible. The cutting head needed to be rotated 180 degrees to change the remaining bits. Green was positioned on the left side of the cutting head, standing on the crossover conveyor. Allen was positioned on the right side of the head, also standing on the crossover conveyor. Allen stated that the side engine had to be started so the head could be rotated. Hearing this statement, Terry L. Brock, swingman/auger helper, walked around the auger and started the side engine.

When the side engine started, so did the crossover conveyer. The control for this conveyor had been left in the engaged position or was inadvertently engaged during the shutdown of the auger. When the conveyor started Allen stepped off and thought Green would do the same. Brock throttled the engine up, which increased the crossover conveyor speed.

When Allen observed that Greene was caught by the conveyor, he attempted to signal Brock to shut off the engine. Before Allen could get Brock's attention, Green was pulled under the cutting head, across the belly pan and into the throat of the discharge conveyor.

Greene was removed from the conveyor and help was summoned. Emergency medical technicians from the adjacent Premier Elkhorn Coal Co. mine responded. First-aid and cardio-pulmonary resuscitation was administered until an ambulance arrived. The victim was transported to Jenkins Community Hospital where he was pronounced dead.

PHYSICAL FACTORS INVOLVED IN THE ACCIDENT

The investigation revealed the following factors relevant to the accident:

1. James Edward Allen, foreman/auger operator, was an eyewitness to the accident.
   
   
2. The weather was cold and rainy on the day of the accident.
   
   
3. According to testimony it was a common practice at this mine to change auger bits while standing in the belly pan of the auger. Taylor Orr, vice-president of Salem Tool Co.,Inc. stated that this method affords protection from highwall hazards by placing workers under a protective screen.
   
   
4. Operating a Salem S-1500-B auger normally requires two persons. Three persons were working at the time of the accident, changing the normal routine.
   
   
5. The control lever for the crossover conveyor was engaged at the time of the accident. The control lever for the crossover conveyor is located on the right side of the auger (when facing the highwall) (See Sketch). The control lever is not readily within the reach of the auger operator while sitting in the auger operator's seat.
   
   
6. All of the auger controls were self-centering except for the crossover conveyor. The crossover conveyor control consists of a hand-operated lever which must be manually engaged or disengaged.
   
   
7. This augering machine was not provided with any manual or automatic lock-out devices for the crossover conveyor control.
   
   
8. The crossover conveyor was not blocked against motion while maintenance work was being performed.
   
   
9. Taylor Orr, vice-president, Salem Tool, Inc., was present during a portion of this investigation. He stated manual devices to block accidental or inadvertent movement of the controls were provided for the crowd and crossover conveyor levers on augers presently being manufactured, but were not provided on older machines such as this one. He stated these devices could be obtained and installed on the earlier models.

CONCLUSION

The auger helper was fatally injured when the side engine, controlling the auger's hydraulic system, was started, simultaneously setting the crossover conveyor in motion. The victim was pulled across the belly pan into the throat of the discharge conveyor, resulting in fatal injuries.

The accident occurred as a result of the auger being started without all persons being in the clear and moving parts not being blocked against motion while work was being performed.

VIOLATIONS

1. A 104(a) Citation (No. 4509084) was issued on February 12, 1996, due to the auger being started without persons being in the clear and moving parts on the auger were not blocked against motion while maintenance work was being performed, a violation of Title 30 CFR 77.404(c).

Respectfully submitted by:

Jimmy Brown
Coal Mine Safety and Health Inspector

Garey L.Farmer
Coal Mine Safety and Health Inspector

Approved by:

Carl E. Boone, II
District Manager

Related Fatal Alert Bulletin:
FAB96C05