Shoals Mine Metal/Non-Metal

Hoistman said around 6:35a.m. smoke came out of an electrical box under the hoist control station. One of the switches/relays had caught fire. The hoistman immediately put out the small electrical fire. The burnt component had caused a power loss to the hoist controls. Evacuation was initiated due to only having one escapeway.

Hoist operator reported that the hoist operating system had faulted. This made the hoist inoperable. The "on call" electrician was notified and said they wouldn't be able to make it to mine within 30 minutes. I then reported to the MSHA hotline and called for evacuation. No miners were present in the cage or shaft during the incident.

During operation of hoisting rock, an encoder fault had occurred on the hoist, stopping operation. While trying to reset the fault by powering the system down per the instructions of the manufacturer, the drive would not power back on due to the plunger on the contacts not tripping, therefore not giving the reset feedback to the system.

Hoistman reported that when they went to bring the cage down, the controls didn't work. They tried to perform a "soft reset". That didn't clear the faults. We didn't have an electrician on the property to perform a "full reset". I made the decision to evacuate due to only having one escapeway.

Hoist operator started hearing a noise around the drive motor area. They then shut the hoist down immediately until further investigation could be done. The call was made to go ahead and evacuate the miners due to having only one escape route.

Mine 12-00427 evacuated the Mine on 9/27/24 immediately upon receiving confirmation from Frontier Kemper that the Quick Release Safety test procedure for the Skip #1 and Skip #2 were done incorrectly.

The east gate solenoid valve failed causing the hoist man to switch to maintenance mode. The gate did not shut, causing rock to overflow into the skip and cause a pile at the bottom of the shaft. No miners were present in the area of the incident.

During an MSHA inspection the inspector found that the maintenance platform canopy was damaged. The mine took hoist out of service and evacuated the Mine.

Loose guide structure was found on an inspection of the main shaft. The shaft was taken out of service so that the repairs could be made.

During a test run of the escape shaft, an alarm was given, stating the cage was in over travel. The cage went to 387.5' and threw the alarm of over travel on the Tiley system, the appropriate stop is at 386'. The cage was manually brought up past the trip alarm and reset. Another test was conducted and it produced the same results as stated above.

The escape shaft was found to be in over travel. The cage was found to be at 387', the normal position is 386'. The over travel was caught by the Tilley panel and an alarm was given. The cage did not trip the physical over travel switch.

Supervisor was moving rock to top of stockpile when trying to fill in a low spot at the edge of the berm. Made decision to use the loader parallel with the berm and got to close too the fresh fill on top edge. Left side of the loader slid down the edge of the berm landing on the left side of the loader.

Escape hoist had an interlock for down stop preventing the hoist from normal operation. The hoist had tripped the magnetic down stop switch at the mining level but did not return back to the normal position when the cage went back to the surface.

Reported COVID-19 symptoms on 8/10. Self-administered a home test that night which was positive. Felt exposure came from a co-worker. That individual was tested for COVID-19 with a negative result. Shoals area is experiencing community spread at this time so it is difficult to trace origin.

The Mine was experiencing high levels of H2S gas and a inundation of water at HP7 and 96 (containment site) as well as HP5 off 86 (sump) and other areas of the mine downwind of these locations. The Miners were instructed that these areas were restricted.

Duke Energy utility pole that has a small can transformer and a capacitor bank mounted to it was arcing at the base of the pole which caused the utility pole to catch fire at the base of the utility pole. Duke removed power to the capacitor bank and transformer and Shoals Fire Department wet the base of the pole to keep it from igniting again.

Employee was using a pry bar to remove a loader tire from the rim the bar slipped. Employee stepped backwards, and when EE did EE stepped onto the fork of a fork truck behind EE. The fork had mud on its surface. When EE's foot stepped on to the edge of the fork EE's ankle rolled and EE fell. EE's ankle was fractured as a result

Mechanic placed hand in a pinch point between cylinder & pick attachment. Pick was not supported & shifted, pinching mechanic's thumb. Pick was moved to release the mechanic's thumb. The thumb received a displacement fracture & two lacerations, one of which required 5 stitches. The other required 0 stitches. Mechanic was released with restrictions.

For unknown reason the Main hoist would not run. The Miners evacuated via the air/escape shaft. The electricians found the problem to be a loose end coder switch

For an unknown reason, the air shaft escape hoist failed to operate. The mine was evacuated and after an electrician performed maintenance on a relay switch, the hoist became operable.

Electrician pulled a fuse on the Tube Mill in the Mill Kettle building. When he pulled the fuse, it tripped the power to the plant rendering the main hoist inoperable. The miners evacuated via the air/escape shaft.

Phase fault occurred causing the mine escape shaft hoist inoperable. It was found that the cause was related to a dirty contact in a switch.

The main shaft hoist power kicked out after the second man trip was 20' below surface level. The electricians and programmers found that 3 electrical contacts were bad in 2 emergency stop switches. Once replaced, the hoist was fully operational.

The ABB hoist power convertor kicked out and the hoistman could not reset the device. An electrician came over to trouble shoot the problem and found that a relay had dirty contacts. After resetting the power several times, the power kicked in and the hoist was functional. No damage occured to the system.

Noise induced hearing loss(standard threshold shift).

Employee was attempting to step up onto the rear step of the powder wagon. As he did, his foot slipped and he felt a slight sensation in his left hip area. The slip was contributed to mud on the step and worn soles on the employees safety shoes. An internal audit discovered this was not recognized as "reportable" until 4/9/2012.

Uneven ground/pot hole. Individual twisted his ankle and fell to the ground. The accident was not reported until the end of the shift. Initial doctor visit required no treatment or follow up. On 10/5/10, a return visit due to lack of ankle motion resulted in prescribed physical therapy.

Noise Induced Hearing Loss(Standard Threshold Shift Change)

Noise induced hearing loss(Standard Threshold Shift Change).

During a routine inspection of the Mine Air/escape shaft hoist, it failed to energize for additional testing. After contacting an electrician, diagnosis showed a stop relay switch failed to reset after the cage landed at the surface.

During a routine inspection of the escape hoist, a large piece of ice was noticed on the mine guide that prevented use of the shaft. The mine was immediately evacuated and MSHA was contacted. The mine went back into production after the ice melted.

Employee incurred a Standard Threshold Shift Change hearing loss in the Right Ear.

During a routine inspection of the airshaft, mine supervision attempted to activate the escape hoist. Upon activating the switch, the conveyance failed to move. Supervision contacted surface electricians and evacutated the mine.

A mechanic was attempting to access the hinge area of a scaling unit to fix hydraulic oil leak. He exited the cab and chose a path that lead him over the exhaust system, fender and other components. Upon his final step to hinge area, which was soaked with oil, his right foot slipped from under him and he fell approx. 4' to the ground breaking the upper portion of his right arm.

The mine was evacuated at 4:25 p.m. because the main hoist went down due to IO Module fault alarms. Electricians responded and contacted ABB service representatives. On vendor recommendation, a IO Module was replaced and hoist operation was returned to normal. Crew returned underground at 6:25 p.m.

The main hoist went down due to fault alarms. Electrictions responded and reset the hoist. Crew returned to underground at 6:25 p.m.

Electronic drive on hoist kicked-out rendering the hoist inoperable. The Chief Electrician reset the breaker and power system and the hoist became operable. The situation will continue to be monitored.

The skip stuck open due to mud build up. This make the hoist inoperable.

A thunderstorm came through the area knocking out power to the Shoals Plant. The mine hoist was disabled. The mine evacuated due to only one means of entry/exit.

The Mine Maintenance Supervisor was in the process of removing a chain that binds a double entry gate to the surface air shaft. As he was removing the chain, the back side of his right hand struck the razor wire directly above the gates. He received a small laceration. Employee received 3 sutures to close the wound, and a tetanus injection.

The discharge chute below crusher became plugged. the skip was dumped at this time. a high-hopper level limit switch was tripped that disables the hoist. the mine was evacuated due to only one means of entry/exit.

Ee#1 & ee#2 were removing 90lb half moon shaped eccentric cover in preparation for new piece of installation. as the 2 ee's proceeded ee#1 was backing up to ascend a step & his pant leg got caughton the metal step & he fell backwards. Ee#2 (the injured ee) received the complete load & threw it to the side so it wouldn't hit ee#1. As ee#2 did this he pulled his back.

A JAMM OCCURRED IN THE DISCHARGE CHUTE AFTER THE SURFACE DOUBLE CRUSHER ROCK BACKED UP ALL THE WAY TO THE MAIN SKIP DISCHARGE HOPPER THE MAIN SKIPS WERE FULL AND THE HOIST-MAN WAS UNABLE TO DU MP THE LOAD. THIS RENDERED MAIN SHIFT INOPERATIVE.

THE HOIST LOST ELECTRICLA POWER DUE TO THE 4160 VOLT STARTER COIL CONTACTS WERE BAD.

THE HOIST LOST POWER AND THE MINE WAS EVACUATED. THE POWER OUTAGE WAS DUE TO AN ELECTRICAL PROBLEM IN THE HOIST MOTOR CONTROLS. THE CHIEF ELECTRICIAN WAS CALLED THE NEXT MORNING TO ASSESS THE SITUATION. THE ABB COMPANY WAS ALSO CONTACTED. THE ELECTRICAIN REPLACED A FUSE AND THE HOIST POWER CAME BACK ON AND IT STARTED RIGHT UP.

WE EXPERIENCED A LIGHTING STORM THAT CAUSED A POWER OUTAGE. THE HOISTE BREAKER TRIPPED BECAUSE OF THE STORM. THE HOISTEMAN TRIED TO RESET THE BREAKER, BUT IT WOULDN'T BECAUSE IT HAD BECOME OVE R HEATED. ALL MINE PERSONEL WERE EVCUATED VIA THE EMERGENCY SHAFT AND PLANT ELECTRICIAN WERE CALLED TO HANDLE THE BREAKER ISSUE.

THE HOIST WAS SHUT DOWN AND LOCKED OUT BY 2ND SHIFT ELECTRICIAN TO PERFORM PREVENTATIVE MAINTENANCE ON THE MOTOR BRUSHES. WHEN MAINTENANCE WAS COMPLETE THE HOISTMAN TRIED TO ENERGIZE THE HOIST . THE HOIST WAS UNABLE TO TURN ON. THE ELECTRICIAN LOCKED IT OUT AGAIN AND FOUND A LOOSE CONNECTION IN AN INTERNAL COMPONENENT. IT WAS RECONNECTED AND WAS ENERGIZED.

A THUNDER AND LIGHTNING SWEPT THROUGH TOWN ON FRIDAY (5-2-03) A BOLT OF LIGHTNING STRUCK OUR PHONE LINES, IMPAIRING OUR PHONE SYSTEM. THE ABB COMPUTER SYSTEM IS CONNECTED TO THE PHONE LINE AND WHEN LIGHTNING STRUCK, IT CAUSED A POWER SURGE PUTTING THE #1 TERMINAL IMPUT OUT OF COMMISSION.THE MINERS EVACUATED VIA THE EXCAPE SHAFT AND THE PLANT ELECTRICIANS CONTACTED ABB USING A CELL

WE CONTRACTED ABB TO INSTALL A NEW HOIST CONTROLLER & SKIP LOADER PLC. DURING THEIR FINAL COMMISSIONING & PROGRAMMING PHASE A HOIST FAILURE OCCURRED, RESULTING IN THE CHUTE LOADER REMAINING IN THE OPEN POSITION. THE HOIST MAN NOR THE ABB PROGRAMMERS WERE UNABLE TO MOVE THE SKIPS MAKING HOIST INOPERABLE. WE EVACUATED.

IN PREPARATION FOR A PLANNED HOIST RENOVATION INDECEMBER, THE PLANT ELECTRICIANS INSTALLED A SETOF NEW SHAFT SWITCHES. DUE TO UNEXPECTED SENSITIVITY OF THE SWITCHES THE LOADING SHAFT INADVERTE NTLY ACTIVATED CAUSING THE HOIST TO BECOME INOPERABLE.

EE WAS WORKING ON #12 ATLAS DRILL. WORKING SURFACE OF DRILL WAS ELEVATED APPROX 40" OFF GROUND. HE CLIMBED UP THE EQUIPMENT TO RETRIEVE A BATTERY CHARGER USING AN 8" BLOCK OF WOOD AS A STEP LA DDER. AS HE STEPPED DOWN, THE WOOD BLOCK TURNED & EE FELL BACKWARDS & TURNED IN THE AIR LANDING ON HIS LEFT HAND & RIGHT WRIST.

EE WAS ON LIFT PLATFORM OF #17 ANFO LOADER. AS OPERATOR ENGAGED HYDRAULIC SYSTEM TO RAISE TABLE,EE TUMBLED BACKWARDS FALLING ON HIS BACK. A HYDRAULIC HOSE BLEW @ SAME TIME EE FELL, SPRAYING HI M W/OIL. EE STATED HE WAS NOT INJURED BY FALL, BUT BY THE SCRAMBLING TRYING TO GET OUT FROM UNDERNEATH THE LIFTING PLATFORM, FOR FEAR PLATFORM WOULD COME DOWN.

BECAUSE OF A RUSTED BRACKET, A SEMAN SWITCH FELL OFF OF THE TRACK AT THE BOTTOM OF THE SHAFT. THE SWITCH INDICATES THE STOPPING POSITION FOR THE EMERGENCY MAN CAGE.

WHILE GETTING IN A DRILL TO DRILL A FACE, THE EMPLOYEE CLOSED THE DOOR ON HIS LEFT RING FINGER. NOT REALIZING HIS FINGER WAS IN THE DOOR HE TRIED TO PULL HIS FINGER OUT OF THE DOOR, CAUSING A LACERATION & DISPLACING THE BONE.

DURING ROUTINE INSPECTION OF THE EMERGENCY AIR SHAFT CONVEYANCE HOIST, IT WAS DISCOVERED THAT THE EMERGENCY BRAKE RELASE WITCH WAS OUT OF ADJUSTMENT AND ROPE SLACK DEVICE WAS TRIPPED, RENDERIN G THE HOIST INOPERABLE.

ELECTRICAL WIRE WENT TO GROUND CAUSING HOIST TO STOP OPERATING. PROBLEM WAS DIAGNOSED AND REPAIRED AND HOIST WAS BACK IN OPERATION IN 40 MINUTES.

A SWITCH AT THE BOTTOM OF ESCAPE SHAFT WAS FOUND TO BE FAULTY DURING ROUTINE INSPECTION.

HOIST ROPE SLACK SWITCH TENSION WAS OFF.

A POWER OUTAGE OCCURED UPON RE-ENGERIZING OF THEHOIST, IT WAS FOUND THAT A 800AMP MAIN FUSE & A 5AMP OUTPUT CORD FUSE FLEW RENDERING THE HOIST INOPERATIVE. THE HOIST WAS DOWN FOR 35 MINS

EE WAS RODDING OUT #3 LAND PLASTER BIN. A LONG HEAVY ROD WITH A BEND AT THE END OF IT WAS USED TO DISLODGE HARDENED MATERIAL. WHILE RODDING ON THE BIN W/FORCE, PART OF THE MATERIAL GAVE WAY. T HE ROD PROCEDDED TO GO DOWN INTO THE BIN, PINCHING THE EE'S FINGER BETWEEN THE ROD AND THE HAND RAIL.

LOOSE SODDER CONNECTION ON CIRCUIT BOARD ON MINE HOIST.