mm0 ' '■...' . M t ( I*- -id V' < ' ' . ' - « ««tii ^|:-;J;^:. ^>:M N -^ O - - - >,-.^.\»*- %--';r;^%o' ~v-T:*s-.-y' '■-■^■'\'p v'--^- ^o-rf^'^'^o'^ \''.?^-\/ V*^-'\°'' V'':^'\^^' ^o^**-rrr.'- ^^' V-^ "^^ 0^ r'"^^-. '^o v^ %*^^'y ..\"^^*^*'y'^ ""v'^'^V %''-^'\^^' -<='^ '- ^°-v.. 4 O ^''•^^. .-^^ o*"'* ^^ • °- /.-^i-X o<'\.>;^.> y\.^:..\ c°*.^i^."°o ^^•n^ >~ . 1 • I IC ®®^^ Bureau of Mines Information Circular/1982 Computerized, Remote Monitoring Systems for Underground Coal Mines Fires and Explosive Atmospheres By Jeffrey H. Welsh UNITED STATES DEPARTMENT OF THE INTERIOR ;'v«i '■^W'' |«!SfaM.&.r'«u ()«•"'■•") Information Circular 8875 Computerized, Remote Monitoring Systems for Underground Coal Mines Fires and Explosive Atmospheres By Jeffrey H. Welsh UNITED STATES DEPARTMENT OF THE INTERIOR James G. Watt, Secretary BUREAU OF MINES Robert C. Norton, Director i^^ A^ ^^ ,i'\ >o> i^ <, This publication has been cataloged as follows: Welsh, Jeffrey H Computerized, remote monitoring systems for underground coal mines: fires and explosive atmospheres. (Information circular ; 8875) 1. Coal mines and mining— Fires and fire prevention. 2. Mine safety— Equipment and supplies. I. Title. II. Series: Information circular (United States. Bureau of Mities) ; 8875. TN295.tF44TN315] 622s [622 '.8] 81-607584 AACR2 1) CONTENTS Page Abstract 1 Introduction 1 Applications 2 Needs for early detection 2 Comparison of safety regulations 3 lOlC petitions 4 Analysis of regulations 5 Conclusions 9 TABLE 1. Analysis of regulations 6 COMPUTERIZED, REMOTE MONITORING SYSTEMS FOR UNDERGROUND COAL MINES Fires and Explosive Atmospheres By Jeffrey H. Welsh 1 ABSTRACT This report presents a study on the use of computerized, continuous remote monitoring systems for fire and explosive atmosphere safety in underground coal mines. The effects of these systems on the safety level in mines are investi- gated, and the relationship between mine safety regulations and computerized, con- tinuous, remote monitoring is analyzed. INTRODUCTION Computerized, continuous, remote mine monitoring systems (CCRMMS) have the potential for improving safety in under- ground coal mines, as well as increasing production and productivity. Commer- cially available equipment exists to mon- itor most mine parameters affecting fire and explosive atmosphere safety. Sensors are available that detect methane, carbon monoxide, and airflow. To analyze data from these sensors, microprocessor-based computers are on the market that can manipulate data and transmit information at high speed. Each mine's physical characteristics and problems are different; therefore, the needs for mine monitoring systems are unique for each specific case. For ^Operations research analyst, Pittsburgh Research Center, Bureau of Mines, Pittsburgh, Pa. example, gassy mines with severe meth- ane problems must maintain adequate ventilation throughout the mine to dilute methane accumulations, and operators may need to monitor the status of the fans, air velocity, and methane concentration to insure that safe conditions are main- tained. Mines working high-volatile coal seams may need a system for rapid detec- tion and location of fires. Mines with bad roof conditions may require detection and location of roof falls before they become a serious problem to the ventila- tion system. MDnitoring the environment for these parameters not only has a safety implication but also has a bene- ficial impact on production, since proper use of the information may avoid costly mine shutdowns and production delays. Once a monitoring system is in place, it can also be used for other purposes such as production monitoring, energy manage- ment, and maintenance control. APPLICATIONS A brief examination of how CCRMMS are being used at several mining conpanies in the United States follows. Example A2 has nines with greater than 2,000 ft overburden, that are very gassy and have difficult roof control problems. Because of this situation, the com- pany has petitioned the Mine Safety and Health Administration (MSHA) , and has received permission to use the belt haulageway for intake air to ventilate the face, providing it continuously monitors for CO in the belt haulage- way. The company has installed variable-pitch ventilation fans and intends to monitor methane and airflow in the returns, and modify the fan pitch accordingly, to reduce ventilation costs. Future plans include monitoring the temperature and vibration df fan bearings, production tonnage, power usage, and belt operation and failure diagnostics. A similar situation exists at exam- ple B, where a variance has been received for use of beltways for intake air to ventilate the face because of heavy over- burden, roof control, and methane prob- lems. Because of this variance CO is being monitored on the beltway. Other parameters being monitored include bear- ing temperature and water gage on the main ventilation fans, with future plans for monitoring methane and airflow in the returns. At example C, the mine has extremely bad roof and methane gas problems. A chief concern is the possibility of roof falls that may disrupt ventilation and cause a methane accumulation. A seismic system is used to detect and locate roof falls through triangulation. Fan pres- sure, methane concentration, CO concen- tration, and air velocity are also being monitored. NEEDS FOR EARLY DETECTION Major fires and explosions in mines have had a fairly low frequency of occurrence in recent years; however, when they do happen, the results can be extremely devastating with regard to both loss of life and property damage. Con- trol of a mine fire, or dilution of an explosive gas, depends almost entirely on rapid detection, decision making, and communication of information to ^Taken from a trip report of Bolt Beranek and Newman, Inc. , to various mines with monitoring systems installed. [U.S. Bureau of Mines (USBM) contract J01 00039/ "Guidelines for Environmen- tal Monitoring in Coal Mines." For more information, contact J.H. Welsh, Technical Project Officer, Bureau of Mines, Pittsburgh, Pa.] underground personnel. An analysis of the Allen report^ data (1970-77) showed ^McDonald, L. B., and R. M. Baker. An Annotated Bibliography of Coal Mine Fire Reports. Volumes I through III. BuMines Open File Rept. 7(1)-(3)-80, Feb. 15, 1979, 1147 pp.; available for reference at Bureau facilities in Den- ver, Colo. , Twin Cities, Minn. , Pitts- burgh, Pa., and Spokane, Wash.; the National Mine Health and Safety Academy, Beckley, W. Va.; and National Library of Natural Resources, U.S. Dept of the Interior, Washington, D.C. Available from National Technical Information Service, Springfield, Va. , PB 80 — 140197 (set), PB 80 — 140205 (v. I); PB 80 — 140213 (v. II), PB 140221 (v. Ill); contract JO275008, Allen Corp. of America. that a fire detected within 15 minutes of development resulted in no, or a minimum of, damage to the mine, 7 3 percent of the time."^ In high-volatile coal, fires over 2 hours in duration usually involve the coal seam, and extinguishing the fire becomes very difficult. In most mines, miners and mining activity are absent from a large portion of the physical area, and the distance from the working area underground to the surface is great. Therefore, rapid detection and location of fires is very important in order to control the fire and provide enough time for miners to escape. As it is for fires, early detection of the buildup of an explosive gas is very important. The explosive range of methane is between 5 and 15 percent. The presence of 1.5 percent methane in the air current returning from active under- ground working places may indicate that considerably larger concentrations of methane may be accumulating in places through which the current of air has passed. In 1966, seven men lost their lives in an explosion in West Virginia as a result of electric equipment being energized and operated without conducting examinations for gas at the beginning of a coal-producing shift, although a pre- shift examination of the working places had been conducted within 2 hours prior to beginning the shift. More recently, in 1976 at Scotia No. 1 mine and in 1980 at Ferrell No. 17 Mine, undetected accumulations of explosive gas were ignited, killing 26 at Scotia and 5 min- ers at Ferrell. COMPARISON OF SAFETY REGULATIONS Presently, mining regulations in the United States do not deal with the use of CCRMMS. Such systems may be used, in many cases, only as a supplement to existing CFR (Code of Federal Regula- tions) requirements, or if a lOlC peti- tion is granted, in lieu of existing requirements. In other countries, the safety and production benefits of CCRMMS are recognized, and provision is made in the regulations for CCRMMS. A few spe- cifics of the regulations of other coun- tries^ are given below: ^Analysis was performed on correlation runs of computerized Allen Report data for mine fires occurring between 1970 and 1977; analysis performed by the National Bureau of Standards under U.S. Bureau of Mines contract JO 100053, Systems Approach to Mine Fire Safety. ^North American Mining Consult- ants, Inc. Single Entry Long- wall Study. U.S. Dept. Energy, contract ET-77-C-0 1-9052. 1. Regulations in France, Poland, and Germany permit higher methane thresh- old values if constant methane monitor- ing is carried out by permanently installed recording instruments that fea- ture teletransmission of results, 2. Regulations in West Germany, the United Kingdom, the U.S.S.R. , and Poland require continuous monitoring of all return airways from coal faces and entry headings by means of permanent methane monitoring devices, with data transmis- sion to central mine control stations and with automatic switch-off devices, 3. Regulations in Canada and Europe contain safeguard monitoring measures for auxiliary ventilation systems based on automatically functioning airflow and methane monitors. 4, Regulations in Germany prescribe the use of automatic-recording CO- measuring instruments in all belt entries. lOlC PETITIONS As mentioned previously, in order for a mine operator to use CCRMMS in lieu of applying current safety requirements, he must be granted a lOlC petition by MSHA. Several lOlC petitions that have been granted are briefly described below. 75.305 Petitions filed under this regu- lation requested waiver of the requirement that air courses be examined in their entirety, because of hazardous roof condi- tions or falls. The petitioners want to establish checkpoints in the air courses where a person would take measurements. One petition requested to use a methane moni- tor to continuously sample the return air in addition to establishing air measure- ment stations. An audible alarm would alert mine personnel when the methane monitor detects methane above 1 percent. 75.307 Petition requested permission to install a methane monitoring device on permissible electric water pximps operating in face areas, to monitor for methane, instead of having a qualified person make the methane tests just before electrical equipment is energized. During normal pro- duction shifts, when the methane detector-equipped pumps are oper- ating, methane examinations would be made at intervals of at least 20 minutes, and the petitioner would examine for methane at least every 8 hours during non- production shifts when the pumps are operating. 75.310 Petitions for variance requested permission to install a methane monitor that would continuously test the methane content in the coal mine and would automatically deenergize electric face equip- ment when the monitor is not operating properly or when the methane content reaches a speci- fied level (either 1.9 or 2 per- cent) . The sensor head is to be located in the split entry not more than 200 ft outby the face area in one petition, and in the other two, a permissible sensor head is to be located in the return aircourse of the air split to be monitored at a point just inby the location where that split joins another. In one petition, a certified person is still required to make frequent inspections of the methane moni- tor at least every 2 hours during its operation and a qualified person is required to make tests for methane in the active working face after each shuttle car is loaded, or at intervals of not more than 15 minutes. The other two petitions required weekly calibration and functions test only. Petitioner stated that the alternative system proposed would assure a reliable and constant, rather than intermittent, methane testing system during mining operations and would reduce the human failure element. The sys- tem would also provide a quicker notification time period to deenergize all equipment. 75.326 Petitions requested permission to use the beltway to ventilate the active workings. By installing an early warning and telemetry system to detect CO and excessive heat in the belt haulage entries, the same measure of protection is provided the miners as by the regulation. The CO detecting devices must be set to monitor at not more than 5 ppm above ambient to indicate warning level, and at not more than 10 ppm above the warning level, evacuation shall be effected when a fire occurs in the belt entry. The automatic fire detection system must upon activation provide an effective warning signal at a manned loca- tion on the surface where person- nel have an assigned post of duty and have telephone or equivalent communication with all persons who may be endangered. The auto- matic fire detection system must also provide identification of any activated sensor. The detector located at or near the section loading point must acti- vate when CO is detected and give a warning signal that may be heard on the working section. 75.1105 Petitions requested waiver of the requirement that air venti- lating transformer stations, battery charging stations, sub- stations, compressor stations, shops, and permanent pumps must be coursed directly into the return. Most of the petitioners wanted to add fireproof material and structures, fire doors, fire suppression devices, and some requested to add a remote alarm at a manned location, which would indicate the location of the fire so personnel under- ground could be notified. ANALYSIS OF REGULATIONS To determine the role of CCRMMS in providing an increased safety level in mines and to determine the relation- ship between mine safety regulations and CCRMMS, an analysis of CFR, Title 30, Subparts D (Ventilation) and L (Fire Protection) was made. The results are displayed in chart form in table 1. 2. level. How CCRMMS affects mine safety 3. If CCRMMS can be used in lieu of current requirements. 4. Review 10 IC petitions request- ing use of CCRMMS in lieu of current requirements . The analysis includes: 1. Function a CCRMMS can perform (both required and not required). It should be noted that it is assxmed by this analysis that the CCRMMS is operational, available, and accurate at all times. 1 , • 1 3 1 3 1 tvl , 1 1 1 3 N I u e e 1 C « d • 10 . 3 « 3 . d a to C c , >< T3 3 1-4 o iH iH C • iH d X • c d d d • d d •H d x: o d • 4J c to 4J 1-1 •o 4-1 O CO 4-1 o • to o •rH o to •H o 4H o •H 4- o to X 10 o J CO O 01 3 O 0) ■J OJ 3 k OJ ^ X kl 01 3 P OJ o u ■J > •H O 01 3 >>« « 4-1 to c 4J ■J o" 4-1 ■J 01 d o- o -J to OJ o -J cr O J 4-1 •J OJ X 4-1 y tr 4> ce 9 •H u-l 3 •H 10 01 •H 10 D. o OJ 4- CO Uh 4-1 to 01 4-1 10 'H 10 ex ao OJ 10 OJ u u i c 4J c V4 c u-l u d u-l to T3 kl Uh 10 ■H UH kl •H Uh d UH CO d d Uh kl ■J o m n o 3 c o u o I-l d d c kl Uh 4-1 d kl d kl o kl d •H to O kl c 00 UM E to CO • E 3 00 B 3 •H to ao O 3 •H d o 3 ao O 3 a 3 ■H kl 4-1 a 3 00 ■^ Jl B m c CO d to -O d B CO 01 B CO d B CO CO 3 d to d AJ •H U-I •J 01 T) U-l 3 0> 1-1 01 4-1 10 •H 00 B •H u 4J ta OJ OJ iH c 1-1 u o •H ^ 0) o o J3 T3 4-1 rO T) kl 4-1 0) X) d 01 OJ XI 4J 01 XI .jO X) kl B XI T3 4J n) 3 o u c c 01 to 01 0) XI to ,r> OJ •rH rH .Q u to J3 OJ u 01 01 u OJ to u ao to -D c 00 Ji ■a c iH -a d I— 1 d •H d d a. d •H d t3 d I-H d rH T3 d 'rH u 1— ( c o • .— 1 to c t— 1 c X M d to to X X d •H a. ■t3 d X X3 d I-H d 10 •rH cx r-H d X o 01 c ■H c c 3 B 1-1 o; 3 to 01 3 § OJ to S 3 • rH CO 01 I-H CO 3 to B ex • to 01 (M > o c 00 o o c ^ O B O -o OJ B p C/2 to 3 B 3 S O a XI 3 to 6 B ^ u 3 4-1 tu C 4-1 E •H 01 d kl kl 4-1 01 4-1 4J B -H 11 kl 4-1 OJ •^ E c ^ 01 c 01 >^ 1— 1 C 0) >% 01 I-H >> •rH kl ■rH U >> iH 01 >, U >, 01 00 •rH OJ >-, rH i-> « ^ v B CO CO c E 1— 1 D. B I-H 4J to a B rH 3 3 a iH o. a rH B I-H 4-1 to d 3 B rH a =2 > o ■J to 3 > o CO CO D. to CO to XI o. ct CO XI U tr to to D. CO CO 10 10 to X) 10 cr CO to a. c T) 1.1 to l- o 5 •r-l I-l 3 3 kl 3 >^ kl 3 k 3 •rH 'J 01 iH 3 3 kl 3 kl 3 >. kl x: 01 kl 3 3 o « o. U-I CO 3 4-1 CO o C/l 10 O C/l to 1/3 ct o < o kl CO O en to o 10 O lyj 10 J M CO O C/3 ~ o Oj a. Oi a D-, Oi D-, P- to 01 1 CO CO 1 kl d 00 >-l iH 0) kl d 3 u 4-1 P 3 -rH o ex CO • O 4-1 J -rJ d O I-H CJ OJ O CX iH 4-1 •r-l I-l r~t OJ 4J CO 4J •r^ D. CO iH CO u 4J T3 4-1 OJ Uh T3 d CO 01 OJ U-l to OJ -H a, CO 3 O O d •H OJ I-H d •rH CO a 3 OJ o I-l -D d kl C/2 X c/: •H to CO cx tr CO UH .d a (U 0) a y 4-1 § to B 01 OJ ^ 4J 00 c c c c 2 •H c S •H 3 d d 0^ OJ d c o o c o 3 c o B d. o o t_ a •H z ■z z 2 o 2 o z z C- a: c u^ 4-J .^ o c U-i 11 O W u^ B Cf CO 01 to CO s: o a) a 0) o C o c o (U o 0) O 01 (U S L4 >- >' z z z 2 2: >H z >H 2 >H U! 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CO • d -i-i MH B CJ 3 CO to IH ra >, d ^4 CO o • 3 iJ O >J 1 CO B 13. a, H 0) CO • OJ OJ •H to o to • o >, u u D. O XJ CO 00 ^ 4J 0) U CJ 01 C^ MH )H * O 0) 3 Qi .. 01 d OJ .. to o .. CO CJ 00 ■rl to d CO OJ CO CO to CO ^^ CjO 6 O > CNl a. 4-1 m E •H o 0) X OJ O CO to 4-1 o 01 XI o OJ _4 ^ O OJ 1-1 ^H ■H S ^-t 4-1 0) •—1 -a 3 iJ -H 3 IJ to •H m d rH V4 — ' 01 to M Q — ^ CO CO '-* 3 Q "H d rJ 3 CJ -H O H a: 03 4-1 a. CO -I •H to u-1 U-1 m LO u-1 tn r^ r~ r^ r^ r^ r^ u to 3 on (1) d X •H 4-1 4-1 tn OJ •rl ■o X 3 0) rH o x: OJ 00 OJ d •rl rH MH 4J •rl to •H rl CO X 3 OJ T rH CO Vj to CONCLUSIONS 1. CCRMMS can perform a wide vari- ety of possible functions that affect both safety and production, 2, CCBIMMS is capable of increasing the safety level in the mine since: (a) Monitoring is continuous and can detect hazards occurring in between periodic examinations, (b) Parameters not required in the CFR can be monitored, which may be site specific. (c) It performs diagnostic functions that reduce shutdown time on fans or other equipment critical to mine safety, (d) It provides location of hazards or problems, that allows for quick corrective action and aids in the escape of miners. (e) Detection is rapid to allow time for correction of hazards and for escape of miners, (f) Alarms are sent to a manned location on the surface, where a person is on duty who can communi- cate with personnel underground to notify them of the hazard and aid in their escape, 3. CCRMMS can be used to perform CFR requirements, in lieu of certain spe- cific requirements, or to supplement these requirements. This use varies with each regulation, A lOlC petition must be granted to use CCRMMS in lieu of CFR requirements. 4, CCRMMS: There are some limitations of It is difficult and expensive to design a practical CCRMMS to be used in high-traffic, congested areas such as the face. Because the face continuously advances, the mon- itoring system would have to be con- tinuously advanced. Design of such a system would require an innova- tive engineering effort. Regula- tions prohibit the use of CCRMMS in place of many measurement require- ments by specifying manual measure- ments; this greatly reduces cost benefits. INT.-BU.OF MINES, PGH., PA. 25984 4s 62 iO-r ^"•n*.. V •^•-0^ -M^'- ^oV^ :"^lia.'-. "-^i-o^' :iSl^'- ^o/ X./ y^A'. U^A^ :a^: \./ .•^'. %,** .-Jfe-. \/ . bl." '..c' ,0' V '^0^ ^oV h- r^^ '.-^K^: ^^^-^^ <> *'7Vi* ,0 .-m^: -^^Z ,^^, .,^^,* ,^-, *.,^^/ ,^.. .,^^,. <> *'Tr «<-' 4, c v^ . • • • s^' ... ''°^/*-^ ' • . » aO -^^ '. -^^-o^ : -^^0^ %'^-' ^^' . "^^^'-^'-y "o^*^-%o^ %''^^\<,'''^ "°^*^-'fO' V'^^'* 7^ /►