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 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 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 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 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 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.