In the matter of Petition for Modification
Jim Walter Resources, Inc.
No. 5 Mine Docket No. M-97-128-C
AMENDED PROPOSED DECISION AND ORDER
Petitioner’s No 5 Mine, located in Tuscaloosa County, Alabama is currently operating under a modification of the application of 30 CFR 75.1002 granted in Docket No. M-85-045-C. The modification was issued on August 4, 1987, and became final on September 15, 1987.
On October 10, 1997, Petitioner filed a request (Docket No.M-97-128-C) to amend Paragraph 11 of the previously granted modification Docket No. M-85-045-C. As indicated in MSHA’s investigation report, the Petitioner requests that Paragraphs 9 and 11 be amended to allow a higher circuit breaker setting and to allow high-voltage cables on longwall sections to be spliced, repaired and vulcanized by properly qualified and trained high-voltage personnel. Additionally, comments were received requesting that Paragraph 12 be amended to include the wording of more recently granted modifications. MSHA agrees that Paragraphs 9, 11, and 12, as well as the other terms and conditions contained in Docket No. M-85-045-C, should be modified to include the same protection to miners as is provided in other modifications. Therefore, all the terms and conditions, with the exception of item Nos. 1, 2, 3, and 20, in the granted modification (Docket No. M-85-045-C), have been amended to reflect current petition requirements which provide the same level of protection as provided by the standard.
The Petitioner alleges that the alternative method outlined in the amended petition will at all times guarantee no less than the same level of protection provided by the standard. This PDO (Docket No. M-97-128-C), when final, shall supersede the modification granted for 75.1002 in Docket No. M-85-045-C.
MSHA personnel conducted an investigation of the amended petition and filed a report of their findings and recommendations with the Administrator for Coal Mine Safety and Health.
Finding of Fact and Conclusion of Law
The alternative method proposed by the Petitioner (as amended by the recommendations of MSHA) will at all times guarantee no less than the same measure of protection afforded the miners under 30 CFR 75.1002.
On the basis of the petition and the findings of MSHA’s investigation, Jim Walter Resources Inc., is granted an amendment of the modification of the application of 30 CFR 75.1002 to its No. 5 Mine.
ORDER
Wherefore, pursuant to the authority delegated by the Secretary of Labor to the Administrator for Coal Mine Safety and Health Act of 1997, 30 U.S.C., sec. 811(c), it is ordered that Jim Walter Resources, Inc.’s request for amendment of the application of 30 CFR 75.1002 as granted in Docket No. M-85-045-C in the No. 5 Mine is hereby:
GRANTED, conditioned upon compliance with the following special terms and conditions.
1. The nominal voltage of the longwall power circuit(s) shall not exceed 2,400 volts.
2. The nominal voltage of the longwall control circuits shall not exceed 120 volts.
3. Ground-fault current for the 2400-volt circuits shall be limited by a neutral grounding resistor to not more than 6.5 ampere or the setting specified in the longwall approval documentation, if less.
4. Each-high voltage motor circuit and shearer shall be provided with instantaneous ground-fault protection set at not more than 40 percent of the ground-fault current limited by the neutral grounding resistor or not more than 0.125 ampere, whichever is less.
5. The high-voltage circuit(s) from the longwall power center to the starter enclosure shall be provided with ground-fault protection set at not more than 40 percent of the ground-fault current limited by the neutral grounding resistor or 0.125 ampere, whichever is less. A time delay may be permitted for coordination with the downstream ground-fault protection devices. The time delay shall be set at the lowest practical value that permits reliable coordination; however, in no case shall the time delay exceed 0.25 second.
6. The longwall power center shall be provided with backup ground-fault protection that shall de-energize the 2,400-volt circuit breaker in the power center if a ground-fault occurs with the neutral grounding resistor open. This protection shall be set at 40 percent of the maximum voltage that could appear across the neutral ground resistor if a ground-fault occurs. A time delay for coordination with downstream ground-fault protection devices shall be set at the lowest practical value that permits reliable coordination; however, in no case shall the time delay exceed 0.25 second.
7. The high-voltage neutral grounding resistor shall be provided with protection that will de-energize the longwall power center if the grounding resistor is subjected to a sustained ground-fault. The protection shall not be dependent upon control power and shall be either a thermal protection or a current transformer and overcurrent relay in the grounding resistor circuit that will de-energize the incoming high-voltage circuit supplying the power.
8. Each high-voltage motor circuit shall be provided with instantaneous short circuit protection set at not more than the setting specified in the longwall approval documentation or not more than 75 percent of the minimum phase-to-phase short-circuit current available at the motor terminals, whichever is less. A time delay of not more than .050 second may be permitted for motors with high inrush currents. All components that provide short-circuit protection shall have sufficient interrupting rating to safely interrupt the maximum calculated available fault current.
9. The 2,400-volt circuit(s) from the longwall power center to the longwall controller shall be provided with short-circuit protection by means of a high-voltage circuit breaker in the longwall power center. This circuit breaker shall be set at not more than 75 percent of the minimum phase-to-phase short-circuit current available at the longwall controller or the setting specified in the longwall approval documentation, whichever is less. A time delay may be permitted for coordination with downstream short-circuit protection devices. A time delay shall not exceed the setting specified in the longwall approval documentation, or 0.25 second, whichever is less.
10. Where two high-voltage cables are used to supply a common bus in the longwall controller and each cable has an overcurrent relay, each overcurrent relay shall be set at an appropriate value determined by the number of relays used. A time delay may be permitted for coordination with downstream short-circuit protection devices. The time delay shall not exceed the setting specified in the approval documentation, or .25 seconds, whichever is less.
11. Circuit interrupting devices shall not reclose automatically.
12. Where two high-voltage cables are used to supply power to a common bus in the longwall controller, each cable shall be provided with an MSHA accepted ground-wire monitoring system. The ground-wire monitoring system shall de-energize both cable(s) when the grounding or ground-wire monitor conductors of either cable becomes severed or open. One circuit breaker shall be used in the power center to protect both cables. The cables shall be interlocked such that the circuit breaker will open when either cable is disconnected.
13. The longwall power center shall be equipped with a primary visible disconnecting device installed to de-energize the primary of the high-voltage transformer(s) when open.
14. The longwall power center shall be equipped with a secondary (2,400-volt) disconnecting device installed to de-energize all high-voltage cables extending to the longwall controller when the device is open.
15. The longwall controller shall be provided with a main visible disconnecting device installed to de-energize all high-voltage power conductors extending from the enclosure.
16. Each disconnecting device shall be installed so that:
(a) It can be determined by visual observation that the disconnecting device contacts are open without removing any covers;
(b) All high-voltage power conductors can be grounded when the disconnecting device is in the “ open” position;
(c) The disconnecting device can be locked in the open position; and
(d) If a cable coupler is used as a disconnecting device, connect the phase conductors in the high-voltage cable to a frame common to the enclosure by means of the grounding receptacle provided and place a dust cover on the enclosure receptacle from which the cable was disconnected.
A sign shall be located near each switch identifying the circuits(s) that the device disconnects.
17. Each 2,400-volt cable installed as a part of the longwall mining system shall be type SHD-GC or other similar cable that meets the requirements of 30 CFR 75.804, with a minimum rating of 5000 volts, and shall have an outer jacket that has been accepted by MSHA as flame resistant.
18. Any high-voltage longwall cable with damage to the extent that any metallic component of the cable is displaced or damaged shall be immediately removed from service and repairs shall be made by a qualified person (as provided in 30 CFR 75.153). Splices and repairs in high-voltage cables shall be made only by a qualified person (as provided in 30 CFR 75.153) who has received “hands-on” training in the proper methods of splicing and repairing high-voltage cables. Splices and repairs shall be made in a workmanlike manner and in accordance with the instructions of the manufacturer of the splice or repair materials. The high-voltage cable outer jacket shall be vulcanized with flame-resistant material, that has been accepted by MSHA as flame-resistant.
When the damage is only to the outer jacket and no metallic components are misplaced or damaged, the outer jacket may be repaired with MSHA accepted flame-resistant material provided that the cable outer jacket is vulcanized on the first idle shift after being repaired.
19. High voltage cables shall be guarded at the following locations:
(a) Where miners regularly work or travel over or under the cables;
(b) Where the cables leave the cable handling and support systems to extend to electrical components; and
(c) Where cables are in the same raceway as low voltage cables.
The guarding shall protect the cables from damage and shall minimize the possibility of miners contacting the cables. The guarding shall be of grounded metal or reinforced nonconductive, flame-resistant material. Additional guarding, unless the high-voltage cable is de-energized, shall be provided on high-voltage cables in belt conveyor entries during cleanup and belt structure removal if the cables are within 12 inches of mobile equipment.
20. Cable handling and support systems that are designed, installed, and maintained to protect the high voltage cables from damage shall be used to minimize the possibility of miners contacting the cables.
21. Adequate means to secure the connection box or in-line connector at mid-face shall be installed to provide secure connections of the high-voltage cables.
22. Energized high-voltage cables shall not be handled except when the shearer cable needs to be trained (shearer cable inadvertently coming out of the cable trough). When the shearer cable needs to be trained, high-voltage insulating gloves or high-voltage insulating sticks shall be used for protecting against shock hazards. Miners shall not handle any other high-voltage cables.
High-voltage personal protective equipment, including rubber gloves, shall be visibly inspected before each use. High-voltage rubber gloves shall be field air tested before each use to ensure their effectiveness. Damaged or defective protective equipment shall be removed from the mine or destroyed. A sufficient storage facility shall be provided for the cable handling equipment. The storage facility shall be clearly marked to indicate its purpose and examined weekly to assure protective equipment is present. Insulated personal protective equipment shall be rated for a minimum of 7,500-volts and electrically tested every six months in accordance with a nationally recognized standard.
23. Barriers shall be provided and covers shall be arranged so that miners can work in the 2,400-volt section of the power center or starter enclosure without being exposed to energized high-voltage conductors or parts, including capacitors, when the appropriate disconnect switch is in the “open” and “grounded” position.
24. Barriers shall be provided and covers shall be arranged so that miners can work in the control compartment(s) of the power center without being exposed to energized conductors or parts that exceed nominal 120 volts (except for the capacitance tripping circuit) regardless of the position of the main disconnect switch.
25. Barriers shall be provided and covers arranged so that miners can work in the motor contactor compartments of the longwall controller without being exposed to energized high-voltage conductors or parts that exceed a nominal 120 volts when the main disconnect switch is in the “open” and “grounded” position.
26. Barriers shall be provided and covers arranged so that miners can work in the communication and control compartments of the longwall controller without being exposed to energized conductors or parts that exceed a nominal 120 volts regardless of the position of the main disconnect switch.
27. Cover interlock switches shall be provided to automatically de-energize the incoming high-voltage circuit to the power center, when any cover that provides access to energized high-voltage conductors or parts, including capacitors, is removed.
28. Cover interlock switches shall be provided and wired to automatically de-energize the 2,400-volt circuit supplying power to the longwall controller, when any cover providing access to 2,400-volt conductors or parts is removed. This condition does not apply to covers installed on motor junction boxes.
29 The control circuit for the power center shall be interlocked with the primary disconnecting device in the power center so that:
(a) When the primary disconnecting device is in the “open” position, the control circuit can only be powered through an auxiliary switch in the “test” position; and
(b) When the main disconnecting device is in the “closed”position, the control circuit can be powered only through an auxiliary switch in the “normal” position.
The control circuit shall be interlocked with the main disconnecting device so that attempting to close the main disconnecting device while in the “test” position shall cause the incoming high-voltage power to be de-energized.
30. Caution labels shall be installed and maintained on the covers of the compartments of the longwall power center enclosure containing the main disconnecting device to warn miners against entering these compartments before de-energizing the incoming power. Also caution labels shall be installed and maintained on all covers that provide access to 2,400-volt conductors and parts to warn miners against entering these compartments before all 2,400-volt capacitors have been discharged. A means shall be provided to ground these capacitors. Also, when low or medium voltage equipment can be energized with the input disconnect in the open position, caution labels shall be installed and maintained on the covers of the compartments to warn miners that the input disconnect only de-energizes high-voltage circuits.
31. Caution labels shall be installed and maintained on the covers of the compartments of the longwall controller main disconnecting device to warn miners against entering this compartment before de-energizing the incoming power to the shearer.
32. Before any electrical work ( including testing, trouble-shooting and faultfinding ) is performed inside the high-voltage compartments or 2,400-volt compartments of the power center, a qualified person (as provided in 30 CFR 75.153) shall:
(a) Determine that the contacts of the appropriate disconnecting device are “open” and “grounded”;
(b) Lock out and tag the disconnecting device; and
(c) Assure that the capacitors are discharged and “grounded”.
33. Before any electrical work ( including testing, trouble-shooting and faultfinding) is performed inside any high-voltage compartment of the controller or on the high-voltage cables supplying the controller, a qualified person (as provided in 30 CFR 75.153) shall;
(a) Determine at the power center, that the contacts of the secondary disconnecting device are “open” and “grounded”;
(b) Lockout and tag the disconnecting device ;and
(c) Assure that all capacitors have been discharged and “grounded”.
Also, each ungrounded conductor of the high-voltage circuit or cable upon which work is to be performed shall be connected to the system grounding medium.
If a cable coupler is used as the disconnecting device, connect the phase conductors in the high-voltage cable to a frame common to the enclosure by means of the grounding receptacle provided and place a dust cover on the receptacle from which the cable is disconnected.
34. Before any electrical work (including testing, troubleshooting, or faultfinding) is performed inside the contactor compartments for the controller, a qualified person (as provided in 30 CFR 75.153) shall:
(a) Determine that the contacts of the main disconnecting device in the controller are “open” and “grounded”; and
(b) Lockout and tag the disconnecting device in this position.
35. The petitioner’s alternative method shall not be implemented until all personnel who perform maintenance on the longwall have received training in high-voltage safety and maintenance procedures.
This training shall be reviewed as part of the employees annual electrical retraining. Also, all personnel who work in the proximity of the high-voltage equipment or who move high-voltage equipment or cables shall be trained in high-voltage safety procedures. A record of this training shall be maintained and made available to authorized MSHA representatives and to other interested parties.
36. The longwall high-voltage mining equipment shall be MSHA approved.
37. The Petitioner shall notify MSHA before mining equipment is put into service in any subsequent longwall panel. The notice shall advise MSHA of any modification to the equipment and provide a reasonable time for MSHA to schedule an inspection of the equipment if necessary.
38. Methane monitors shall be installed and maintained on the long wall face in accordance with 30 CFR 75.342.
39. Self-contained self rescuers (SCSR’s) shall be stored in the vicinity of the headgate and shall be stored along the face or at the tailgate of the longwall section to meet the requirements of 30 CFR 75.1714.
40. Within sixty (60) days after this proposed Decision and Order becomes final, the Petitioner shall submit proposed revisions for its approved 30 CFR Part 48 training plan to the Coal Mine Safety and Health District Manager. These proposed revisions shall specify task and refresher training regarding the terms and conditions stated in the Proposed Decision and Order.
Any party to this section desiring a hearing on this matter must file in accordance with 30 CFR 44.14, within 30 days. The request for hearing must be filed with the Administrator for Coal Mine Safety and Health, 4015 Wilson Boulevard Arlington, Virginia 22203.
If a hearing is requested, the request shall contain a concise summary of position on the issues of fact or law desired to be raised by the party requesting the hearing, including specific objections to the proposed decision. A party other than Petitioner who has requested a hearing shall also comment upon all issues of fact or law presented in the petition, and any party to this action requesting a hearing may indicate a desired hearing site. If no request for a hearing is filed within thirty days after service thereof, the Decision and Order will become final and must be posted by the operator on the mine bulletin board at the mine.
_______________________________
Robert A. Elam
Deputy Administrator
for Coal Mine Safety and Health