• Safety Innovations Awards

Safety Innovations Awards
Quarry | Milling/Grinding | Pyroprocessing | General Facility



Pyroprocessing

Lehigh Cement Company
Mitchell, Indiana

This plant’s alternative fuels system requires semitrailers to be backed into two unloading bays. The material is then dumped via “walking bed trailers” into a hopper and conveyor system. The challenge was to design a safety rail that could prevent someone from falling into the hopper with a moving conveyor, yet still allow a trailer enough clearance to be backed up to the dump hopper. To address this concern, a retractable guardrail was installed in both dump lanes. The guardrail is spring-loaded and will retract as the trailer backs up, allowing the truck trailer to dump its load into the hopper. When the trailer is pulled out of the dump bay, the guardrail springs back via the spring assemblies to its neutral position, preventing possible falls into the hoppers.

GCC of America, Inc.
Rapid City, South Dakota

This operation has a conveyor belt that transports coal from an unloading station to a transfer storage bin through an 80-ft inclined tunnel. This area was identified as a safety issue due to the potential hazards of a coal dust fire, poor visibility, trip hazards, and the personal protective equipment required while inspecting and washing down the tunnel. Previously, to clean the tunnel of all coal particle dust, the operator had to suit up in coveralls, rain gear, and full face air-breathing mask, then drag a 1-in. water hose through the tunnel. It took three hours to wash down the walls, equipment, and floors to conform to MSHA combustible waste standards. The equipment operators began a search for a better and safer method for cleaning the tunnel system. The operating team devised a water spray system that was placed over and under the belt system via an overhead water line. This water system was set up to also clean the walls and floor, as well as the beltway. The water system’s nozzles are fire suppression units, linked up with pipe, clamps, anchor bolts, and valves. The system is simply activated by opening a set of 2-in. ball valves and starting a single water pump. The operator now starts the water spray system, goes off to do other work, and returns in 15 minutes to shut the system off. This innovation has resulted in a safer way to keep the tunnel and beltway in MSHA conformance. Achieved for less than $1,000, the water spray system provides a shorter cleaning cycle, allows for more efficient use of the operator’s time, keeps the tunnel safe from fires, and no longer exposes personnel to this environment.

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