Millersville Operations Metal/Non-Metal

Unplanned coal dust ignition in the #1 Coal Ball Mill system occurred. No injuries occurred. Property damage occurred to the dust work.

Employee was loading an over-the-road semi-truck when lime entered his left eye. Employee was wearing safety eye wear at the time of injury. Rx Eye Drops were give at hospital.

Unplanned coal dust ignition in the #2 Coal Ball Mill occurred. No property damage or injuries occurred.

At 6:23 PM on 7/1/12 the site lost power shutting down the fuel system. The system was restarted at 8:55 PM on 7/1/12. At 8:55 PM the coal mill experienced an unplanned ignition of the coal in the #1 KFS Ball Mill. No injuries or property damages occurred.

Plant air pressure was reduced below 80 psi causing the emergency air damper to open on K1. This led to a kiln shut down from pulling high ID fan amps. An unplanned ignition of fuel occurred in the fuel system during 1.5 hours post solid fuel addition.

Plant air pressure was reduced below 80 psi causing the emergency air damper to open on K1. This led to a kiln shut down from pulling high ID fan amps. An unplanned ignition of fuel occurred in the fuel system during relight.

At 4:45 p.m. on 9/14/11 the site lost power shutting down the fuel system. The system was restarted at 4:46 A.M. on 9/14/11. At 6:05 p.m. the coal in the mill self ignited causing an explosion. The mill was shut down and inspected. No damage to equipment or personnel occurred due to the safety dampers properly venting the combustion gases.

At 4:45 p.m. on 9/14/11 the site lost power shutting down the fuel system. The system was restarted at 6:52 P.M. on 9/14/11. At 7:00 p.m. the coal in the mill self ignited causing an explosion. The mill was shut down and inspected. No damage to equipment or personnel occurred due to the safety dampers properly venting the combustion gases.

At 11:40 p.m. on 8/24/11 the site lost power shutting down the fuel system. The system was restarted at 3:35 A.M. on 8/25/11. At 8:02 a.m. the coal in the mill self ignited causing an explosion. The mill was shut down and inspected. No damage to equipment or personnel occurred due to the safety dampers properly venting the combustion gases.

At 10:05 p.m. on 8/25/11, the coal in the mill self ignited causing an explosion. The mill was shut down and inspected. No damage to equipment or personnel occurred due to the safety dampers properly venting the combustion gases.

At 8:50 p.m. on 8/6/2011 the site lost power. The power interruption reset the PLC controlling the ID fan and ball mill tempering damper causing a partial system shutdown. At 9:29 p.m. the fuel system was restarted and the coal in the #1 Ball Mill system self ignited. No personal or property damage resulted from the ignition.

Experienced an unplanned ignition of coal in the #2 KFS Ball Mill system. No injuries or damages occurred.

Experienced an unplanned ignition of coal in #2 Ball Mill. At 9:24 a.m. power was lost to the fuel system which prevented the system to be purged as required by the shutdown SOP. The explosion occurred when the mill fan was restarted started. No injuries or damage occurred.

At 1:06 P.M on 3/11/2011 an unplanned ignition occurred internal to K2 coal ball mill. The inlet temperature was not reduced to below 200F per shutdown procedures which led to the unplanned ignition. No injuries or damage occurred.

The employee was walking out of lunch room after punching in and slipped on a patch of ice causing him to turn/roll over his ankle and fall at the edge of the concrete pad. Fractured Ankle/Hard Cast

The site had an unplanned ignition of coal dust in the #2 Kiln ball mill fuel system at 2:07 pm on Feb. 3rd. The ignition occurred when the ball mill fan was started and reached 45% output. No injuries resulted. Minor damage occurred to a pressure relief vent. The event was reported to MSHA at 2:15 pm.

Injury occurred while changing bags on HiVac trailer. Subject and one other employee were pulling out filter cages from the HiVac trailer, when subject pulled a cage out and felt a pain in his back. Received medical treatment on 11/17 - Rx Drugs and Restricted Duty.

While sliding/moving a 3 inch diameter, 20 feet long metal pipe on a hanger, the employee felt a pop and sharp pain in his upper right forearm. The employee was treated for off site medical needs on 3/12/10, was given Rx Drugs and right arm lifting restrictions.

EE was attempting to remove blockage from a tunnel feeder. As he moved the slide, the far side fell off the track. In reaction he attempted to grab the slide. However, the weight of the slide & motion of the belt, wedged his hand between the next feeder & the slide. When he pulled his hand out of the pinch point he lacerated is little finger. He received three stitches @ ER

While removing the kiln burner pipe using a come-a-long, the anchor point to which the come-a-long was connected failed and broke away causing EE to fall to the floor hitting his head and cutting his ear.

Employee was shoveling out (mucking out) the scrubber tank after a morning of stacking 50 pound bags of chemical lime. When he went to get out of the tank he felt a pop in his right shoulder. Employee went out for shoulder surgury on 10/10/08.

Crusher hydraulic sys. failed & oil dripped onto the hot material & ignited. EE put out fire w/ fire extg. Fire would rekindle. Occurred several times, EE call fire dept, knocked heat out so oil not ignite again. Single fire did not burn for longer then 30 min. Report being filed becuase MSHA believes was a reportable fire. 7000-1 is not an admission that a reportable fire occurred

EE was climbing the trackmobil ladder to operate the piece of equipment, when he stepped on the second step his foot slipped. His left arm and stomach slid down hitting the top side corner of the platform. Then his chin hit the top corner of the platform putting a 1.5 inch gash in his chin. The occupational clinic had to put 8 stitches into the laceration on the employees chin.

The employee was shooting a kiln with a Winchester Industrial Tool (Kiln Gun) when a shot ricocheted off the ring, hitting the employee in the throat. The impact caused a laceration that needed two stitches for treatment.

While shooting the iron coating out of the kiln, a slug from the gun ricocheted off the iron coating ring in the kiln. The slug exited the opening where the gun is mounted and struck the employee's forehead. The employee recieved stitches at the hospital.

The employee was lifting fifty pound Ferro bags above his shoulder level when he felt pain in his right arm/shoulder. The employee did not see a doctor until 5-28-04, when the doctor prescribed Rx anti-inlammatory drugs.

EE SPRAINED L. SHOULDER WHILE PUSHING MATERIAL DOWN CHUTE. EE WAS UTILIZING A PRY BAR TO FREE PLUGGED MATERIAL IN STONE CHUTE. EE COMPLETED HIS SHIFT, SHOULDER FELT WORSE AT HOME SO HE WENT TO DR. EE REPORTED TO WORK THE NEXT DAY.

SLIPPED ON ICE BETWEEN SHOP AND ROTARY BUILDING

WHILE GRINDING METAL IN BACK OF SHOP PARTICLES FLEW INTO HIS EYE. HE WAS WEARING PROPER PROTECTIVE GEAR.

EE WAS HELPING INSTALL THE COAL PIPE FOR #1 KILN, WHILE PUTTING 16 INCH ELBOW IN PLACE A BEAM WAS BUMPED CAUSING DUST TO FALL FROM OVERHEAD, COMING DOWN ON TOP OF HIS SAFETY GLASSES.

EMPLOYEE WAS TRYING TO LOCATE LEAK IN MATERIAL TRANSPORT CHUTE WHEN HOT LIME DUST FELL OVER THE TOP OF HIS SAFETY GLASSES AND ENTERED INTO HIS RIGHT EYE.

WHILE AIR LANCING PLUGGED DEBRIS FROM BOTTOM OF CYCLONE, HOT DUST BROKE LOSE, HIT WATER, AND EXPLODED INTO INDIVIDUALS FACE AND ON FOREARMS. INDIVIDUAL WAS WEARING SAFETY EQUIPMENT WITH EXC EPTION OF FACE SHIELD.

EE WAS STANDING ON PLANK PUSHING IN ON WEAR PLATE WHLE OTHERS PLACED NUTS AND BOLTS IN PLACE TO HOLD PLATE. EE SLIPPED ON PLANK AND FELL ACOUPLEOF FEET ONTO A CRUSHER IMPACTOR AND SUSTAINED A FRACTURE (CHIP) ON HIS RIGHT FOOT. THE EXACTY INJURY WAS SMALL CHIP FRACTURE AT THE BASE OF THE 5TH METATARSAL

WHILE CONTRACTOR WAS LOADING UP THEIR EQUIPMENT, THE INDIVIDUAL PINCHED HIS FINGER BETWEEN PUMP BEING LOADED AND TRAILER.

HOT KILN DUST BLOWING AROUND.

WORKING ON WINDSHIELD WIPER ASSEMBLY CHECKING DIRECTION OF PARK POSITION WHEN RIGHT HAND MIDDLE FINGER GOT CAUGHT BETWEEN WIPER DRIVE ARM & WIPER MOTOR FRAME.

MAKING CHANGE OVER AT 6 BIN WALKING AROUND CORNER AND SLIPPED ON WET LIME DUST TWISTING RIGHT KNEE AND MID TO LOWER BACK.

REMOVING COATING FROM #1 KILN WHEN ANOTHER PIECE OF COATING HIT PRY BAR. BAR HIT AND CUT RIGHT FINGER.

WHEN ATTEMPTING TO UNPLUG BRIDGED MATERIAL FROM #2 CYCLONE, HOT KILN DUST BEGAN TO FREE FLOW FROM THE TIPPER DISCHARGE VALVE. EE WAS BURNED BY THIS HOT FREE FLOWING DUST.

EE WAS WELDING OVERHEAD & WAS UNAWARE THAT A SPARK HAD CAUGHT HIS SHIRT ON FIRE. AS A RESULT, EESUFFERED SEVERE BURNS TO HIS LEFT UPPER ARM & ARM PIT AREA.

WHILE HOISTING A KILN GUN ONTO THE BURNING FLOOR, THE GUN SLIPPED OUT OF ITS CLAMP, CATCHING AND TWISTING THE RING FINGER ON HIS RIGHT HAND.

WHILE WORKING IN A BUCKET ELEVATOR, A BLOCK OF WOOD FELL FROM THE TOP OF THE ELEVATOR (APPROX. 60') AND HIT RIGHT WRIST. STITCHES WERE REQUIRED FOR CUT.

ON 9/2/95 AT APPROXIMATELY 2:00AM A FIRE BROKE OUT IN #1 RAYMONDMILL COAL BIN. THIS FIRE LASTED UNTIL 9:OO AM WHEN IT WAS EXTINGUISHED WITH THE ASSISTANCE OF THE HELENA COMMUNITY FIRE DEPT. TH E CAUS OF FIRE IS UNKNOWN.

WHILE CHANGING SCREENS ON 5X14AC UNIT EE PULLED A MUSCLE (STRAIN) IN HIS LOWER BACK

EMPLOYEE FELL OFF A SMALL PLATFORM, APPROX. 18" OFF THE GROUND. AS HE FELL HE TRIED TO CATCH HIMSELF, AND HIT HIS LEFT HAND ON A TABLE LEG THAT WAS SETTING NEAR THE PLATFORM. AS A RESULT OF TH IS FALL, EMPLOYEE RECEIVED A HAIRLINE FRACTURE IN HIS LEFT HAND.

EE WAS REMOVING OVERSIZED MATERIAL FROM A MOVING CONVEYOR WHILE STANDING ON AN I-BEAM WHICH WAS APPROX 5FT ABOVE AN ELEVATED WALKWAY AFTER STANDING IN AN AWKWARD POSITION FOR SEVERAL MINUTES H IS LEGS FELL ASLEEP AT THIS TIME HE ATTEMPTED TOMOVE FROM AREA HIS LEG GAVE OUT & HE FELL LODGED HIS LEFT HAND INTO A ROTARY AIR LOCK ALL FINGERS & A PORTION OF HIS LEFT HAND WERE SEVERED

EMPLOYEE WAS CARRYING A SMALL OIL TORCH ACROSS THE FIRING FLOOR. AS HE WENT AROUND THE CORNER OF THE CONTROL ROOM HE TWISTED HIS BODY AROUND AND FELT A PAIN IN HIS LOWER BACK.

WHILE OPERATING A OVERHEAD HOIST AND MANEUVERINGFORKS TO LIFT A PALLET INJURED TWISTED HIS RIGHTKNEE AND AGGREVATED A PRE-EXISTING CONDITION. HIS PREVIOUS INJURY WAS NOT WORK RELATED AND OCC URRED BEFORE SHAWN BEGAN WORKING FOR REDLAND OHIO.

WHILE BAGGING 50# FERRO BAGS HE PULLED A MUSCLE IN LOWER BACK.

WHILE RAKING A COATING AT A #2 COOLER THE EMPLOYEE PULLED A MUSCLE IN HIS BACK.

THE EE WAS CLIMBING UP A LADDER TO PLATFORM AREA IN ORDER TO INSPECT MOQENSEN SCREEN UNIT. UPON REACHING PLATFORM, EE RAISED UP QUICKLY AND STRUCK HIS HEAD ON A BLDG SUPPORT BEAM.

INJURED WAS PULLING COATING BALLS WITH A RAKE AT THE END OF #2 COOLER, WHILE HE WAS PULLING ON A BALL, ANOTHER BALL HIT THE RAKE KNOCKING IT LOOSE FROM TEH BALL AND THE HANDLE OF THE RAKE HIT INJURED'S GROIN AREA.

THE EE WAS WORKING ON THE BRICK CREW DURING A SHUTDOWN. HE WAS INSIDE THE KILN AND HAS HE STARTED TO EXIT, THE PLANK ROLLED OVER AND HE FELL APPROX. 12 FEET LANDING ON HIS BACK ON TOP OF A PIL E OF LIME IN THE NORTH END OF THE COOLER.

WHILE CLEANIGN THE RETURN CHUTE TO #2 COOLER, HOT MATERIAL FELL INTO RIGHT SHIFT SLEEVE BURNING HIS ARM.

A PRODUCT BUCKET ELEVATOR STOPPED. EMPLOYEE HURRIED TO THE TOP TO INSPECT THE DRIVE BELTS. HE SOMEHOW MIS-STEPPED AND FELL INTO THE LADDER OPENING. HE DID NOT FALL DOWN THE LADDER. HE CAUGHT H IMSELF, BUT HITTING AGAINST THE CATWALK STEEL.

WHILE WORKING ON ASCREEN UNIT, DUST WAS BLOWN INTO HIS RIGHT EYE.

WHILE PERFORMING CONSTRUCTION WORK, A STEEL CHANNEL WAS LOWERED TO THE NEXT FLOOR LEVEL. THE EMPLOYEE'S HAND WAS AT A PINCH POINT CATCHING HIS FINGER BETWEEN THE MOVING AND FIXED STEEL WORK.

IN THE ATTEMPT TO REMOVE A KILM COOLER GRATE BY HOISTING WITH CHAINFALL TO SLIDE THE GRATE OUT THRU THE OPENING. THE GRATE SLIPPED. HITTING LEFT FOOT. LITTLE TOE.

68935 ATTEMPTING TO REMOVE A MOTOR FROM A VIBRATING SCREEN,THE RIGGING SLIPPED,ALLOWING THE MOTOR TO DROP ONTO THE EMPLOYEES HAND.

INJURED WAS GREASING BEARINGS ON TOP OF AN ELEVATOR WHEN DUST WAS BLOWN INTO HIS LEFT EYE

AFTER OPENING THE AIR BREAK TO WORK ON A TRANSFORMER EMPLOYEE CLIMBED TO TOP OF TRANSFORMER UNBEKNOWN THAT THE AIR BREAK HAD A BROKEN INSULATOR ONE LEG OF THE AIRBREAK FELL TO CLOSED POSITION GIVING THE EMPLOYEE AN ELECTRICAL SHOCK

EE ATTEMPTED TO FREE AN IDLER WHILE CONVEYOR BJELT WAS RUNNING CONVEYOR IS PROPERLY GUARDED HE REACHED FOR THE IDLER WITH RIGHT HAND WEARING A COTTON GLOVE HE DOES NOT KNOW IF A SPLICE BRABBED HIS GLOVE.

THE INJURED WAS PULLING COATING BALLS AT THE PRIMARY COOLER WHEN A PIECE OF DUST BLEW INTO HIS RIGHT EYE.

WHILE CLEARING CHUTE FROM DUST CHAMBER DUST PARTICLES BLEW INTO LEFT EYE.

SLIPPED OFF THE BOTTOM RUNG OF THE LOADER LADDER, LANDING ON HIS FEET.

GRINDING STEEL SM PC FLEW OFF WENT IN R EYE

THE EMPLOYEE WAS REMOVING FLY ASH COATING INSIDE THE KILN DUCT WORK WHEN A LARGE PIECE BROKE AWAY AND ROLLED OWN THE EMPLOYEES LEFT SIDE.

THE EE WAS MOVING A BULKHEAD INSIDE A RAILROAD BOX CAR. WHEN THE BULKHEAD WAS BEING MOVED, IT CAME DOWN ON TOP OF THE EE STEEL TOE SHOE AND PUSHED THE BACK EDGE OF THE CAP ONTO HIS TOE.

WHILE ATTEMPTING TO SPOT A RAILROAD CAR IN LOADING SHED.RAILROAD CAR DERAILED-LEAD END OF CAR WAS OFF TRACK FOR APPROXIMATELY 70 FEET UNNOTICED BY BRAKEMAN AND LOADER OPERATOR.BY THE TIME OF I MPACT THE CAR WHEELS WERE OFF THE TRACK 48 INCHES,HITTING BUILDING STRUCTURE(I-BEAM)PINNING VICTIMS LEG BETWEEN CAR AND BEAM.

HANDING BRICKS BRICK FELL OUT OF RING HITTING HIM ON HIS HARD HAT CUT ABOVE R EYE 4 STITCHES

EMPL 1 REMOVING ECCENTRIC WHEEL THAT WAS 7' OFF GROUND.HANDED WHEEL DOWN TO EMPL 2 WHO WHILE LOWERING WHEEL HIT BACK OF HAND ON REEVES DRIVE HANDLE.

THE INJURED WAS LOOKING INTO THE PRIMARY COOLER TO REMOVE COATING WHEN A PIECE OF HOT DUST BLEW INTO HIS RIGHT EYE.

THE INJURED WAS REMOVING COATING FROM #2 COOLER, WHEN A PIECE OF LIME DUST BLEW INTO HIS LEFT EYE.

WHILE CLEANING OUT A FEED BOX OF A BUCKET ELEVATOR WITH A STEEL BAR ELEVATOR BUCKET AND BAR CAME IN CONTACT PINCHING THUMB BETWEEN BAR AND ELEVATOR HOUSING

WHILE TIGHTENING BOLTS ON AN ELECTRIC MOTOR EMPLOYEE WAS PULLING ON WRENCH THE WRENCH SLIPPED STRIKING HIMSELF ONTO FOREHEAD.'

WHILE ATTEMPTING TO D ISLODGE LARGE STONE IN PRIMARY CRUSHER FEEDER PULLING ON STONE HOOK GUIDE ROPE EMPL FELT PAIN IN BACK.

EMPL WAS USING LARGE HAMMER & PUNCH BUTTING HOLES INTO RUBBER BLETING. HAMMER GLANCED OFF BELT PUNCH STRIKING LEFT HAND.

WHILE ATTEMPTING TO REMOVE BUCKET FROM PAYLOADER EMPL WASS HOLDING PIECE OF BARSTOCK WHILE ANOTHER EMPL WAS SWINGING SLEDGE HAMMER TO DRIVE OUT HINGE PIN. HAMMER GLANCED OFF BAR STOCK STRIKIN G LEFT HAND OF EMPL.

WHILE WORKING ON A HINGED PLATFORM,THE EMPLOYEE STEPPED THRU AN OPENINF CUTTING HIS SHIN OF THE LEFT LEG.

I.NAME DISLODGING LARGE CHUNK OF KILN COATING USING HOOK AND PULLING CHUNK DOWN SLOPED GRIZZLEY.WHILE PULLING ON ONE PIECE OF COATING ANOTHER BALL ROLLED DOWN ONTO I.NAME LEFT FOOT.

EMPL IN SITTING POSITION WELDING ON PRIMARY CRUSHER IMPELLER BARS.SPARK-SLAG-DROPPED ONTO LACE/TONGUE OF SAFETY BOOT BURNING THRU TO SKIN.EMPL WAS WEARING LEATHER APRON AND PROTECTIVE FOOT SHI ELDS.

THE INJURED WAS CLIMBING UP A RAIL CAR LADDER-MISSING HIS GRIP AT ABOUT SIX FEET ABOVE GROUND FALLING BACKWARD.

WHILE CLEANING SCREEN CLOTH USING A METAL CLEANER-RIGHT THUMB WAS SMASHED BETWEEN METAL OBJECT AND SCREEN BODY-CAUSED A SMASHED THUMB AND ON 12-11-87 IT WAS DIAGNOSED (THUMB) TO THE BROKEN.

WHILE DRIVING A3PICKUP TRUCK WEST SIDE OF CRUSHER HOPPER INJURED WAS LOOKING TO HIS LEFT CONCERNED ABOUT A QUARRY HAULER PULLING AWAY WITH DUMP BED UP AT THE SAME TIME A LOADER OPERATED AT ST OCKPILE INJURED3HIT LEFT BACK TIRE OF LOADER NEARLY HEAD ON

EMPL REMOVING M5TERIAL CHUTE 4'' PLASTIC PIPE.WHILE LIFTING BOTTOM END OF CHUTE,TOP END UNHOOKED AND SWUNG AROUND STRIKING EMPL ON LEFT SIDE OF FACE.EMPL KNOCKED TO GROUND INJURING PUNCTURING RIGHT KNEE. 3

EMP ON BRICKING3CREW ATTEMPTED TO PULL OFF GLUED ON SHIM FROM BRICK HAND SLIPPED CATCHING THUMB NAIL UNDER SHIM WITH FORCE THUMB NAIL WAS RIPPED LOOSE

THE INJURED AND3HIS C/-WORKER ATTEMPTED TO LOAD A 15 FOOT LONG PIECE OF SWITCH RAILROAD RAIL ONTO A TRUCK. WHILE SLIDING THE RAIL TOWARD THE TRUCK, THE RAIL ROLLED OVER, PINCHING THUMB BETWEE N THE TWO RAILS1

EMPLOYEE ASSIST9D CHANGING OF WATER COOLED SAMPLE PROBE FROM FEED END OF ROTARY KILN IT WAS ASSUMED ALL WATER WAS DRAINED BUT WHILE CARRYING SOME REMAINING HOT WATER FROM PROBE SPILLED ONTO RT LEG AND KNEE 3

EXACT TIME, NOR PLACE OF INJURY UNKNOWN. EMPLOYEE WORKED ON TWO PROJECTS THAT DAY-A PLACING CONCRETE AND B) CLEANING CONCRETE MIXER. RIGHT EYE BECAME MORE INFLAMMED DURING THE NIGHT AND EMPLOY EE WAS SENT TO DOCTOR AM 7-19-85. DR. REMOVED EMBEDDED PARTICLE FROM IRIS.

IN ATTEMPTING TO OPEN COOLER VENT DAMPER PINCHED FINGER BETWEEN DAMPER ARM AND STACK.

EMPLOYEE WAS PLUGGING A HOLE IN ELEVATOR AND GOT HIS SECOND FINGER LEFT HAND, CUT ON BUCKET.

TURNED AROUND AND WALKED INTO CUTTING TORCH BUGGY WHICH PUSHED SAFETY GLASSES INTO LEFT SIDE OF HEAD, CAUSING LACERATION.