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By F. C. Trutt, J. Sottile, J. L. Kohler

Presented in this paper is a theoretical review of the relationships that should exist between electrical winding parameters and the mechanical vibration of a-c machine elements under normal and faulted operating conditions. Also included is data from an experimental study that relates stator vibration and bearing vibration to selected winding faults in a synchronous machine. Consideration of these results indicates a significant relationship between electrical deterioration and mechanical vibration and thus provides the motivation for additional study and a basis for future applications.

By Fred N. Kissell

The U.S. Bureau of Mines was established in1910 to reduce .the high accident rate in the nation's coalmines. For 85 years, it conducted a wide variety of tasks related to mining before it was abolished in 1995. The BOM had many technology transfer successes in its lifetime, including more than a dozen "R&D100" awards. This essay identifies and discusses five "transfer factors" that can explain the success (or failure) of many Bureau of Mines projects. These five factors are termed "pressure, pitfalls, path, price, and profit."

By Andrew B. Cecala

While various types of equipment are used in bulk material processing plants to control respirable dust, the equipment often doesn't adequately protect workers. One cost-effective way to supplement your existing dust control equipment is to install a whole-plant ventilation system. This article outlines research by the National Institute of Occupational Safety and Health (NIOSH) on using whole-plant ventilation in two mineral processing operations to reduce respirable dust levels. Information also covers how to design a ventilation system for any bulk material processing plant.

By Frederick C. Trutt, Jeffery L. Kohler, Joseph Sottile

Twenty-five years ago, the former U.S. Bureau of Mines funded a research project aimed at developing the enabling technology for incipient failure prediction in electric power system components as a means of reducing the injuries and fatalities that sometimes occur when equipment malfunctions. Over the ensuing years, interest in this has waxed and waned, but recently interest has been growing for both civilian and military applications. This paper addresses the level of turn-to-turn insulation deterioration that can be resolved using an on-line monitoring technique. The detection of turn-to-turn defects is especially important because they are believed to represent the beginning stage of most motor winding failures.

By F. W. Jones

The perturbation of alternating electromagnetic fields by three-dimensional structures is considered. The general model is that of a semi-infinite conducting half -space which consists of regions of different conductivities. A numerical method is used to obtain the solution for the equations and boundary conditions. The effects on the fields at the surface of the half-space due to the conductivity discontinuities are shown by three-dimensional amplitude and phase plots.

Jan 1, 1973

Background: The National Institute for Occupational Safety and Health (NIOSH) recently investigated ignition incidents resulting from drilling holes into sealed and filled plow frame sections. A farmer and farm worker were seriously burned in two separate incidents that occurred in the same county in New York under similar conditions. They had just penetrated sealed sections of their plow frames with electric drills when a roar of escaping gas at high pressure was heard, and the victims were thrown back by the gas jet and engulfed in flames. The flames were quickly extinguished ,but the victims suffered burns. NIOSH experts were asked to help find the cause of these hazardous incidents.

Jun 1, 1998

By T. Brady, R. Langston, J. C. Johnson, H. Kirsten

An experiment is described in which instrumented rock bolts were used to measure strain in the rock mass during drift development at the Stillwater Mine, Nye, Montana, USA. Two strain-gauged rock bolts were grouted into the middle of the rib next to the face. The drift was excavated in three advances, each one-half drift wide. Strains were recorded hourly by a data logger. Results show that the average change in axial bolt strain for the first and second advance was about the same and that there was almost no change in strain after the third advance. Bending strain was observed 19 cm from the head of the bolt.

By W. D. Monaghan, G. L. Mowrey, C. W. Ganoe

In addition to developing various types of coal-interface detection system, the US Bureau of Miner is actively in involved in developing a coal rib-thickness monitoring system for highwall mining applications. One particular system that shows promise in a ground-pentetrating radar system to detect the coal-air boundaries of coal rifts. Based on preliminary laboratory and field tests results indicate that this method can be applied successfully in highwall mines to maintain constant rib thickness. The coal seam should be relatively clean in the vicinity of the antenna (e.g., have minimal partings or dirt bands) for best results.

By Maria I. De Rosa

This report analyzes mine fires for all U.S. underground and surface coal mining categories by state and 2-year time periods during 1990-1999. Risk rate values are derived, and ignition source, methods of fire detection and suppression, and other variables are examined. The data were derived from Mine Safety and Health Administration (MSHA) mine fire accident publications and verbal communications with mine personnel. The analysis will provide the National Institute for Occupational Safety and Health, MSHA, and the mining industry with a better understanding of the causes and hazards associated with mine fires and will form a basis for future fire research programs.

Jan 1, 2004

By Launa Mallett, Charles Vaught, Jr. Brnich

This paper introduces a technique for incorporating employee participation into the prevention component of a contingency plan. Companies sometimes focus so much energy on response that they forget to put resources into the basics of emergency prevention. The training program discussed here was designed to make employees part of the prevention system. Examples of training materials from the program are provided, a sample method for introducing risk assessment to employees is shown, and a strategy to address limited training time using short videos is explained. Methods for tailoring the training to any worksite and for specific risks are also included. The program is being designed and tested by the Pittsburgh Research Laboratory/NIOSH and employees of an underground coal mine. Examples are taken from the implementation of the program at the mine during the summer and fall of 1998. Results of the program evaluation and lessons learned during the implementation are discussed.

By Thomas H. Dubaniewicz, Gerald R. Cucci, Gregory M. Green, Kenneth L. Cashdollar

New types of industrial instruments use fiber-coupled law energy to power remote serum. Fiber-optic based instruments are useful in classified (hazardous) locations found in many industrial plants because the fiber provides a natural barrier against accidental electrical discharge into potentially explosive atmospheres. However, current safety standards do not cover the use of laser-powered fiber-optic instruments in potentially explosive environments such as found in coal mines. The U. S. Bureau of Mines began an investigation of laser-powered fiber-optic instruments in explosive atmospheres in support of the standards-making process. A commercial fiber-optic interface system, modified to sin relate several worst-case operating conditions, ignited explosive hydrogen-air mixtures. Worst-am simulations consisted of disabling a safety shutoff feature, operating the laser at significantly higher powers than intended for normal operations, and cleaving fiber-optic connections to direct laser energy onto selected absorptive materials. At the highest power level available, the fiber-optic interface system did not ignite selected methane-air mixtures. The obtained data should prove useful in establishing appropriate safety standards.

By Jack Wasserman, Don Wasserman, Gretchen Hinton, Logan Mullinix, Shekar Khanal

Human testing has always been a needed way to provide information on the effects of vehicle vibration, however, the manner of testing has not reflected the real situations of driver’s hands on a steering wheel and a seat with back support and driving tasks. The typical system have used a standard sinusoidal excitation rather than the typical types of road – truck excitations The new truck driver training simulators provide the combination of road roughness, speed effects, cab environment and individual tasks. The system has a full six axis simulation potential. The simulators have the protection of the individual by a combination of two ways for the individual to stop the motion as well as an operator with visual capability who can stop the testing. The closed simulator, shown in Figure 1, has the potential for providing motion during the operation.

Jan 6, 2006

By Eric Zahl, John Dunford, Hamid Maleki

Coal bumps are defined as sudden failures of rock and coal near entries that are of such a magnitude that they expel large amounts of material into a mine opening. Coal bumps are influenced by geologic conditions, the geometric design of coal mine excavations, and the sequence and rate of extraction. Researchers from private industry and the National Institute for Occupational Safety and Health have studied mechanisms of violent failure and have identified individual factors that contribute to coal bumps. In an attempt to develop tools for assessing coal bump potential, the authors initiated a comprehensive study using information from 25 case studies undertaken in U.S. mines. Multiple linear regression and numerical modeling analyses were used to identify the most significant variables contributing to coal bumps (excluding bumps related to fault-slip). Twenty-five geological, geometrical, and geomechanical variables were considered initially. The most important of these variables were then identified as (1) energy as calculated using the mechanical properties of the strata, depth of overburden, and joint density, (2) mining method, (3) pillar factor of safety, and (4) stress gradient and yield characteristics.

By T. M. Barton

This paper presents several case studies in which a mechanics-based boundary-element program is used to back-calculate the surface subsidence associated with various panels at several northern Appalachian coal mines. The program used in this case study is called LAMODEL, which incorporates a frictionless, laminated overburden into a general-purpose displacement-discontinuity code primarily designed for calculating the stresses and displacements in coal mines or other thin-seam or vein-type deposits. In this paper, the program is used to calculate both the underground convergence and the resulting surface subsidence at five longwall panels and a room-and-pillar section. The fitted subsidence from the model is compared with the field measurements and analyzed. The results from this work show that the LAMODEL program is not as accurate as available empirical subsidence-predictive methods: the expected correlation between the geology and the optimum input parameters is not evident. However, for a mechanics-based program, LAMODEL does provide moderately accurate subsidence calculations, and it is one of a few programs that can even attempt to practically calculate both underground stress and convergence and the resulting surface subsidence.

This report was prepared by Jacob Tolsma and Arnold N. Johnson of the Uniroya 1 Research Center, Wayne, New Jersey. The valuable assistance and suggestions of the project officers, Mr. Ronald D. Hill, Dr. David R. Maneval and Mr. John J. Buscavage is gratefully acknowledged. The authors are grateful to the following Uniroyal personnel: Mr. Daniel Shichman, manager of Engineering Research, and Dr. Emmanuel G. Kontos, manager of the Polymer Physics Research for their direction, encouragement and suggestions regarding the experimental work, and Mr. Mark Olson for the design of the hollow auger soil sampler. We also wish to gratefully acknowledge the efforts and contributions of ideas proposed by our consultants, Dr. Frank T. Caruccio, assistant professor of geology at State University College, New Paltz, New York, and Dr. Pa Ho Hsu, associate professor of soil chemistry, Rutgers University , New Brunswick, New Jersey.

Jan 1, 1972

By Dennis Dolinar, Russell Frith, David Oyler, Christopher Mark

Unusual circumstances may require that a longwall retreat into or through a previously driven room. The operation can be completed successfully, but there have been a number of spectacular failures which exposed miners to serious roof fall hazards. To help determine what factors contribute to such failures. the National Institute for Occupational Safety and Health (NIOSH) compiled a comprehensive international database of 130 case histories. The cases include five failures where major rock falls occurred in front of the shields, and six even more serious failures involving major overburden weighting. This suggests two room failure mechanisms The first is a roof fall type failure caused by loading of the immediate roof at the face as the fender narrows. The second is a weighting type failure caused by the inability of the roof to bridge the recovery room and face area, and affecting rock well above the immediate roof The data indicate that the roof fall type of failure is less likely when intensive roof reinforcement (bolts, cables, and trusses) is employed together with higher-capacity shields The overburden weighting failures, in contrast, occurred when the roof was weak and little standing support was used

By Joseph E. Chilton, Robert J. Timko, Charles D. Taylor

No regular monitoring of methane is required in areas of gassy coal mines outby the mining face. Methane ignitions that have occurred in mine outby areas indicate the need to provide better protection to workers. Handheld methane monitors are now used by some miners to make periodic measurements of methane at the working face. The IYONI II gas detector which is incorporated into a miner’s cap lamp and worn on a miner’s helmet can continuously provide an alarm signal whenever methane levels exceed a set level. Tests were conducted to evaluate the performance characteristics of this methane detector by measuring response times with methane gas supplied through a calibration fixture or adaptor. Other response time tests were performed with the detector in an environmental test box. Performance was also evaluated in a full scale test gallery where face methane emission and underground ventilation were simulated. Procedures for calibration by response time measurement of the IYONI II detector have been developed. In limited testing, the IYONI II detector was found to reliably detect the presence of 1 percent by volume methane.

By Gerald T. Homce, Michael R. Yenchek, H. Kenneth Sacks, James C. Cawley

Abstract—Overhead electric power lines present a serious electrocution hazard to personnel in a variety of industries. Overhead lines, typically uninsulated conductors supported on towers or poles, are the most common means of electric power transmission and distribution, and are exposed to contact by mobile equipment such as cranes and trucks. Equipment contacting energized overhead lines becomes elevated to a high voltage, and simultaneous contact by personnel of the “hot” frame and ground can cause serious electrical shock and burns. Industries where risk of these accidents is greatest include construction, mining, agriculture, and communications/public utilities. An estimated 2300 accidental overhead line contacts occur each year in the U.S. This paper describes a practical low-cost concept to detect actual contact of mobile equipment with a high-voltage line and provide a warning. Accident statistics indicate that more than half of the fatalities could be prevented by such a device. Index Terms—Crane, electrical shock prevention, engineering control, mining, mobile equipment, power line.

By Erica E. Hall, Robert H. Peters, Charles Vaught, Jon C. Volkwein

Coal workers’ pneumoconiosis is the leading cause of death due to occupational illness among U.S. coal miners. This disease is caused by miners’ exposure to excessive levels of respirable coal mine dust. A personal dust monitor (PDM) has recently been developed to provide near real-time feedback to miners regarding the level of respirable coal dust in the air they breathe. The main objective of this report is to document coal miners’ reactions to this device and how they make use of the information it provides. It summarizes a field study by the National Institute for Occupational Safety and Health that documented the opinions of 30 miners at 4 underground coal mines concerning the use of PDMs.

Jan 2, 2008

By Michael J. Sapko, Gregory M. Green, Harry C. Verakis, Kenneth L. Cashdollar

The National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted a joint survey to determine the range of coal particle sizes found in dust samples collected from intake airways of U.S. coal mines. The last comprehensive survey of this type was performed in the 1920’s. The size of the coal dust is relevant to the amount of rock dust required to inert the coal dust, with more rock dust needed to inert finer sizes of coal dust. Dust samples were collected by MSHA inspectors from several mines in each of MSHA’s ten bituminous Coal Mine Health and Safety Districts. Samples were normally collected in several intakes at each mine. The laboratory analysis procedures included acid leaching of the sample to remove the limestone rock dust, sonic sieving to determine the dust size, and low temperature ashing of the sieved fractions to correct for any remaining incombustible matter. The results indicate that particle sizes of mine coal dust in intake airways are finer than those measured in the 1920’s. The significance of these finer coal dust sizes is discussed relevant to the amount of rock dust required to prevent coal dust explosions.