Helmet-CAM: Strategically Minimizing Exposures to Respirable Dust Through Video Exposure Monitoring.

Exposure to respirable crystalline silica (RCS) remains a serious health hazard to the US mining workforce who are potentially exposed as various ore bodies are drilled, blasted, hauled by truck, crushed, screened, and transported to their destinations. The current Mine Safety and Health Administration (MSHA) permissible exposure limit (PEL) for RCS remains at approximately 100 µg/m3, but it is noteworthy that the Occupational Safety and Health Administration (OSHA) has lowered its PEL to 50 µg/ m3 (with enforcement dates staggered through 2022 for various sectors), and the National Institute for Occupational Safety and Health (NIOSH) has held a 50 µg/m3 recommended standard since 1976. To examine a method for reducing RCS exposure using a NIOSH-developed video exposure monitoring (VEM) technology (referred to as Helmet-CAM), video and respirable dust concentration data were collected on eighty miners across seven unique mining sites. The data was then collated and partitioned using a thresholding scheme to determine exposures that were in excess of ten times the mean exposure for that worker. Focusing on these short duration, high magnitude exposures can provide insight to implement controls and interventions that can dramatically lower the employee's overall average exposure. In 19 of the 80 cases analyzed, it was found that exposure could be significantly lowered by 20% or more by reducing exposures that occur during just 10 min of work per 8-hour shift. This approach provides a method to quickly analyze and determine which activities are creating the greatest health concerns. In most cases, once identified, focused control technologies or behavioral modifications can be applied to those tasks.

Improving protection against respirable dust at an underground crusher booth.

The U.S. National Institute for Occupational Safety and Health completed a 15-month study at an underground limestone mine crusher booth that evaluated three research parameters: (1) the effectiveness of a filtration and pressurization system for improving the air quality inside the operator booth, (2) the relative effectiveness of η > 99 and η > 95 experimental prototype filters in the system, and (3) the performance of three different cab pressure monitoring devices. The protection factor was quantified monthly using particle counters in the respirable dust range of 0.3 to 1 µm particle size, and gravimetric dust samples were gathered at the beginning and end of the overall study. Under static (closed-door) conditions, the filtration unit offered a gravimetric calculated protection factor between 10 and 31, depending on the filter type and loading condition. The monthly particle counting analysis shows that the η > 95 filter offers a protection factor nearly five times that of the η > 99 filter, where n = 15 samples. The booth pressure monitors were tested and proved to be a valid indicator of system performance over time.

Dust Suppression Hopper: reduces dust liberation during bulk loading: Two case studies.

After industrial sand has been mined and processed, the finished product is typically loaded into small bags of 45 kg (100 lb) or less, large bulk bags of 454 to 1,361 kg (1,000 to 3,000 lb), or vehicles such as trucks or trains for transport to end users. As the sand is being transferred and loaded, dust can be released into the work environment, potentially exposing workers to respirable crystalline silica. A number of control technologies have been developed and utilized in an effort to reduce dust liberation during loading operations. For bulk loading into trucks or trains, the U.S. National Institute for Occupational Safety and Health (NIOSH) evaluated one of these technologies, the Dust Suppression Hopper (DSH), at two industrial sand processing plants. Results from these case studies show that the DSH reduced airborne respirable dust levels by 39 to 88 percent, depending upon the product size being loaded.

Quick fixes to improve workers' health: Results using engineering assessment technology.

Personal respirable dust sampling and the evaluation of control technologies have been providing exposure information to the mining industry but not necessarily in a way that shows how technology can be integrated to provide organizational support and resources for workers to mitigate dust sources on site. In response, the U.S. National Institute for Occupational Safety and Health (NIOSH) used previously developed Helmet-CAM technology to design and engage in a behavioral/engineering cooperative intervention to initiate and enhance mine site conversations about the risks and potential occurrences of respirable silica dust exposures on the job as well as provide impetus and solutions for mitigating higher sources of dust. The study involved 48 workers from five mine sites, who agreed to participate between April 2015 and September 2016. Using the Helmet-CAM in this series of longitudinal interventions revealed several exposure trends in respirable silica dust sources and, in many cases, simple quick-fix strategies to reduce their sources. This paper focuses on several specific identified sources of dust that were elevated but could be reduced through basic engineering fixes, low-cost resources, and supportive communication from management to remind and engage workers in protective work practices.

Comparison of MERV 16 and HEPA filters for cab filtration of underground mining equipment.

Significant strides have been made in optimizing the design of filtration and pressurization systems used on the enclosed cabs of mobile mining equipment to reduce respirable dust and provide the best air quality to the equipment operators. Considering all of the advances made in this area, one aspect that still needed to be evaluated was a comparison of the efficiencies of the different filters used in these systems. As high-efficiency particulate arrestance (HEPA) filters provide the highest filtering efficiency, the general assumption would be that they would also provide the greatest level of protection to workers. Researchers for the U.S. National Institute for Occupational Safety and Health (NIOSH) speculated, based upon a previous laboratory study, that filters with minimum efficiency reporting value, or MERV rating, of 16 may be a more appropriate choice than HEPA filters in most cases for the mining industry. A study was therefore performed comparing HEPA and MERV 16 filters on two kinds of underground limestone mining equipment, a roof bolter and a face drill, to evaluate this theory. Testing showed that, at the 95-percent confidence level, there was no statistical difference between the efficiencies of the two types of filters on the two kinds of mining equipment. As the MERV 16 filters were less restrictive, provided greater airflow and cab pressurization, cost less and required less-frequent replacement than the HEPA filters, the MERV 16 filters were concluded to be the optimal choice for both the roof bolter and the face drill in this comparative-analysis case study. Another key finding of this study is the substantial improvement in the effectiveness of filtration and pressurization systems when using a final filter design.

Air cleaning performance of a new environmentally controlled primary crusher operator booth.

The National Institute for Occupational Safety and Health (NIOSH) cooperated with 3M Company in the design and testing of a new environmentally controlled primary crusher operator booth at the company's Wausau granite quarry near Wausau, WI. This quarry had an older crusher booth without a central heating, ventilation and air conditioning (HVAC) system, and without an air filtration and pressurization system. A new replacement operator booth was designed and installed by 3M based on design considerations from past NIOSH research on enclosed cab filtration systems. NIOSH conducted pre-testing of the old booth and post-testing of the new booth to assess the new filtration and pressurization system's effectiveness in controlling airborne dusts and particulates. The booth's dust and particulate control effectiveness is described by its protection factor, expressed as a ratio of the outside to inside concentrations measured during testing. Results indicate that the old booth provided negligible airborne respirable dust protection and low particulate protection from the outside environment. The newly installed booth provided average respirable dust protection factors from 2 to 25 over five shifts of dust sampling with occasional worker ingress and egress from the booth, allowing some unfiltered contaminants to enter the enclosure. Shorter-term particle count testing outside and inside the booth under near-steady-state conditions, with no workers entering or exiting the booth, resulted in protection factors from 35 to 127 on 0.3- to 1.0-µm respirable size particulates under various HVAC airflow operating conditions.

Effects of MERV 16 filters and routine work practices on enclosed cabs for reducing respirable dust and DPM exposures in an underground limestone mine.

An effective technique to minimize miners' respirable dust and diesel exposure on mobile mining equipment is to place mine operators in enclosed cabs with designed filtration and pressurization systems. Many factors affect the performance of these enclosed cab systems, and one of the most significant factors is the effectiveness of the filtration system. High-efficiency particulate air (HEPA)-type filters are typically used because they are highly efficient at capturing all types and sizes of particles, including those in the submicron range such as diesel particulate matter (DPM). However, in laboratory tests, minimum efficiency reporting value (MERV) 16 filters have proven to be highly efficient for capturing DPM and respirable dust. Also, MERV 16 filters can be less restrictive to cab airflow and less expensive than HEPA filters. To verify their effectiveness in the field, MERV 16 filters were used in the enclosed cab filtration system on a face drill and roof bolting mining machine and tested at an underground limestone mine. Test results showed that DPM and respirable dust concentrations were reduced by more than 90% when the cabs were properly sealed. However, when the cab door was opened periodically throughout the shift, the reduction efficiency of the MERV 16 filters was reduced to 80% on average.

Helmet-Cam: tool for assessing miners' respirable dust exposure.

Video technology coupled with datalogging exposure monitors have been used to evaluate worker exposure to different types of contaminants. However, previous application of this technology used a stationary video camera to record the worker's activity while the worker wore some type of contaminant monitor. These techniques are not applicable to mobile workers in the mining industry because of their need to move around the operation while performing their duties. The Helmet-Cam is a recently developed exposure assessment tool that integrates a person-wearable video recorder with a datalogging dust monitor. These are worn by the miner in a backpack, safety belt or safety vest to identify areas or job tasks of elevated exposure. After a miner performs his or her job while wearing the unit, the video and dust exposure data files are downloaded to a computer and then merged together through a NIOSH-developed computer software program called Enhanced Video Analysis of Dust Exposure (EVADE). By providing synchronized playback of the merged video footage and dust exposure data, the EVADE software allows for the assessment and identification of key work areas and processes, as well as work tasks that significantly impact a worker's personal respirable dust exposure. The Helmet-Cam technology has been tested at a number of metal/nonmetal mining operations and has proven to be a valuable assessment tool. Mining companies wishing to use this technique can purchase a commercially available video camera and an instantaneous dust monitor to obtain the necessary data, and the NIOSH-developed EVADE software will be available for download at no cost on the NIOSH website.

Methods to lower the dust exposure of bag machine operators and bag stackers.

This article reviews various dust control technologies developed over the years at the Pittsburgh Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) to provide various options and alternatives to lower bag machine operators' and bag stackers' dust exposures. Dust exposure records for the past 20 years show that bag machine operators and bag stackers normally have the highest respirable dust exposures of workers at mineral processing plants. A substantial amount of research has been performed over the years to minimize the dust exposure to these workers and the intent is to present all this information together in one article. Most of the research describes engineering controls that were adapted to existing facilities to reduce the dust generated during bag filling, bag conveying, and bag stacking. In some cases, a single technique succeeded in lowering respirable dust concentrations for all three processes, thus reducing the dust exposure to both the bag machine operator and the bag stacker. In other cases, a technique was developed to specifically reduce the dust exposure of one process or the other. This research also reviews various controls for secondary dust exposure, including general ventilation requirements to mill buildings, the effects of background dust sources, and personal work practices. This information is presented to help industrial hygienists, plant managers, engineers, and workers lower the dust exposure of bag machine operators and bag stackers.

Reducing workers' dust exposure during bag stacking in enclosed vehicles.

The Bureau of Mines has evaluated cost effective systems to ventilate enclosed vehicles being loaded directly with bagged product material at mineral processing plants. This evaluation included both forms of transportation: railcars and trailer trucks. The goal of this research was to lower the dust exposure of workers stacking bags in these enclosed vehicles; these workers usually have the highest dust exposures in the entire processing plant. The problem occurs because there is no mechanical ventilation inside these vehicles. As the vehicle is being loaded, dust concentrations increase to substantial levels because released dust has no means of exiting the vehicle or of being diluted with fresh air. In cases where the dust is hazardous, as with silica sand, this may present a serious health hazard. This research project was a two-step effort. The first step was a qualitative laboratory evaluation performed in a railcar to compare different types of ventilation systems (blowing, exhaust, and push-pull systems) using a methane (CH4) tracer gas technique. An exhaust system located over the snake conveyor was the most effective system at reducing gas levels in and around the bag stacker's work area. The second step then involved a field evaluation at a silica sand processing plant to determine the system's effectiveness in the actual work environment. Three different versions were evaluated in an attempt to optimize the exhaust ventilation system's effectiveness. The most effective version involved exhausting 54.5 m3/min (2000 ft3/min) through a fiberglass tube located 1.1 m past the end of the slinger at a 2.0-m height so as not to interfere with the bag stacker's job function.(ABSTRACT TRUNCATED AT 250 WORDS)