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Dozer Engulfment Case Study

Dozer Engulfment Case Study. Jack Katlic Sr VP-Fuel Supply, AEP- Retired Mark Skiles Director of Technical Support, MSHA Phil Southern Bodygard Sunnie Southern Bodygard. Dozer Engulfment Case Study. Agenda Surge Pile Hazards Surge Pile Accidents Solutions for Stronger Cab Windows

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Dozer Engulfment Case Study

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  1. Dozer Engulfment Case Study Jack Katlic Sr VP-Fuel Supply, AEP- Retired Mark Skiles Director of Technical Support, MSHA Phil Southern Bodygard Sunnie Southern Bodygard

  2. Dozer Engulfment Case Study • Agenda • Surge Pile Hazards • Surge Pile Accidents • Solutions for Stronger Cab Windows • Demonstration • Conclusion • Panel Discussion

  3. Dozer Engulfment Case Study • Purpose • Share one method the coal industry has implemented to save lives

  4. Surge Pile Hazards

  5. Surge Pile Safety Slides with the MSHA logo were adapted from the MSHA website and can be found at: www.msha.gov Directorate of Technical Support Mine Safety and Health Administration

  6. Surge Pile Hazards • Feeding material acts like “quicksand”

  7. Surge Pile Hazards • The edge of the drawhole is unstable

  8. Surge Pile Hazards • Poor visibility

  9. Surge Pile Hazards • Since 1980, 19 persons have died in coal mining related surge pile accidents • Most of the accidents have involved a hidden cavity created when material “bridged” over a feeder

  10. Causes of “Bridging” Over a Surge Pile Feeder • Bridging can occur • When equipment transverses the material at the surface of the pile • Surface material compacts creating a false roadway • “Settling in” may occur in an idle pile and increase risk

  11. Surge Pile Accidents

  12. Dozer Buried in Cavity Note the thickness of the material that had been bridged over

  13. Partially Buried Bulldozer in Fatal Accident in Pennsylvania A hidden cavity collapsed under the dozer while it was pushing coal on the pile

  14. Most fatal accidents occurred when the dozer cab windows either broke, or were pushed into the cab, allowing coal to fill the cab

  15. Cab Filled with Coal The coal has broken or pushed in the cab windows and filled the cab

  16. Windshield pushed back into cab Note: orange object under windshield is an self contained self rescuer (SCSR)

  17. Best Practices: Ways to Improve Surge Pile Safety

  18. Best Practices: Surge Pile Safety • Provide equipment cabs strong enough to resist burial pressures

  19. Solutions for Stronger Cab Windows

  20. Available Solutions for Stronger Cab Windows • MSHA initiative • Use of very high-strength glass • Massey approach • Add supports to the inside of the cab windows - combined with using somewhat stronger glass • Use of polycarbonate windows • Adequate strength • Support around edges needs to allow for higher deflection • Issue of scratch-resistance • Bodygard system • A customized polycarbonate system

  21. Massey Subkit

  22. Massey Subkit • The first system • Most widely used • Effective in saving lives • System design • is comprised of metal bars attached to the inside of the cab • keep the cab and glass from collapsing on the operator

  23. The Massey Approach • Installed support bars on the inside of the cab windows • The supports for the right-side door window are shown here

  24. The Massey Approach • Horizontal support bars and additional edge support for the windshield are shown here

  25. The Massey Approach • Massey’s successful burial demonstration • The glass cracked but it held the coal out of the cab

  26. Contrast this scene after the Massey demonstration - where coal was held out of the cab - with...

  27. This scene from an accident, where coal has filled the cab...

  28. Advantages Keeps cabs from collapsing Least expensive Saves lives Disadvantages Obscures vision especially when backing up Causes cycildelic affects that result in complaints of headache from operators Metal bars rattle and increase noise level in the cabin Metal bars loosen and crack door glass that must be replaced Massey Subkit

  29. PPG Preformed Pre-designed Product

  30. PPG Preformed Pre-designed Product • Created as by request of MSHA to overcome the deficiencies of the subkit • System design • A chemically hardened preformed pre-designed product • Installed by gluing the glass into a gasket is installed in same manor as standard glass packages

  31. High-strength glass installed using urethane adhesive

  32. Field Burial Demonstration Federal No. 2 Mine Near Morgantown, WV

  33. High-strength glass installed in all cab windows of test dozer

  34. Dozer with high-strength glass being buried in coal pile

  35. Buried dozer being dug out

  36. Checking windows after burial

  37. High-strength glass intact after burial demonstration

  38. Advantages Does not obstruct vision Resists static pressure up to 40 psi Disadvantages Preformed therefore application is limited to Caterpillar and Komatsu dozer’s* standard cab packages Requires fixing of any deformation of the cab prior installation of the glass Most expensive May crack when impacted May pop-out under stress PPG Preformed Pre-designed Product PPG Pounds per square inch *Molds are only for dozers not for end loaders

  39. Bodygard System

  40. Bodygard System • Custom engineered • Custom installed • Polycarbonate system • Outboard seat is created • Material is mechanically attach to the cab • Inhibits internal collapse • Unbreakable • Noise insulator • On site installation • All manufacturers • MSHA approved

  41. Case Study History • Massey conducted drop tests of 3 systems to determine the most effective system • The following demonstration shows the results of the test

  42. Dozer Drop Test Demonstration

  43. Advantages Unbreakable Does not obstruct vision Can be made to fit anything (all makes and models of existing equipment) Absorbs and insulates sound Broad based system Onsite customized installation on all cabs Installed on site by drilling and attaching to cab Cut to specs and attached to ensure stability Disadvantage* Is less scratch resistant that regular glass therefore a protective covering is applied that is easy and inexpensive to replace Bodygard System Body Guard *Protective replicable material is applied to improve the scratch resistance

  44. Conclusion • Based on the results of the drop test, Massey signed a national contract with Bodygard to perform their installations

  45. BODYGARD “The Safety Window People” 1 Lincoln Center, Shinnston, WV 26431 www.bodygard.com 304-592-1980

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