Search Documents

By J. Litsenberger, T. E. Marshall, P. R. Coyle, L. J. Prosser, A. T. Iannacchione

For the first time in an underground stone mine, the relationship between roof movement and microseismic emissions was examined in conjunction with two distinct roof fall areas. As roof monitoring increases in acceptance and monitoring technology advances, the goal of providing reliable roof fall detection systems to enhance the safety of underground mine workers moves closer to reality. Instrumental to reaching that goal is the ability to interpret accurately and completely roof movement and microseismic emissions, which can serve as precursors to roof falls. This paper examines the capabilities of convergence and microseismic monitoring systems to better understand roof rock failure mechanics and to anticipate roof falls. An understanding of how these techniques are used and how they interact with each other is critical in developing the most effective ground control strategy for our nation’s mines.

By Jeffrey Johnson, Thomas Brady, Radford Langston, Mary MacLaughlin, Hendrik Kirsten

The magnitudes and directions of in situ stresses affect the stability of mine openings, as well as the type and amount of ground support needed to maintain a safe working environment for miners. Using hollow inclusion stress cells, researchers from the Spokane Research Laboratory of the National Institute for Occupational Safety and Health obtained two in situ stress measurements from the face of two footwall lateral drifts at the Stillwater Mine near Nye, MT. The first measurement, obtained in 1997, was collected under the valley beneath the Stillwater River. The second measurement was obtained in 2002 under the main frontal massif of the Bear tooth Mountains in the western sector of the mine. Although few data are available, the major principal stress under the valley has been recorded as nearly horizontal in a north-south direction perpendicular to the ore body, while beneath the mountains, stress runs east-west parallel to the ore body. This paper documents the measurements, describes the in situ stress state, and discusses a finite-difference analysis of the biaxial test.

By Christopher C. Jobes, Alan G. Mayton, Farid Amirouche

Based on prior mine vehicle studies of operators’ exposure to whole-body vibration, researchers from the National Institute for Occupational Safety and Health (NIOSH) evaluated four seat designs on mine haulage vehicles, with regard to roadway-induced jarring/jolting and operator comfort. Investigators collected objective and subjective data from vehicle operators on two existing and two NIOSH seat designs. This study included time and frequency response data using accelerometers and a data recorder, operator perceptions of jarring/jolting and discomfort levels using a linear visual analogue scale, and data from a questionnaire developed for this study. Results from the analysis of subjective data show that operators generally favoured the NIOSH-designed seats over the existing seats. The results of analyses from the absorbed power method and the threshold limit method, based on ISO 2631-1 (ISO, 1985), support the premise that NIOSH seat designs are superior to the existing vehicle seat designs on both models of mine shuttle cars used in the study. The NIOSH seat designs, featuring viscoelastic foam padding, were more effective in reducing vibration energy for operators exposed to vehicle jarring/jolting. In this paper, the performances of the NIOSH and existing seat designs are compared relative to the operator’s exposure to vehicle vibration (mainly jarring/jolting).

By Russell Griffin

The current state of the art of fire and smoke detection technology is reviewed from the standpoint of suitability for use in under- ground metal and nonmetal mines. Detection modes, fire signatures, and environmental considerations are included. Preliminary results of long- term, in-mine tests are presented.

By Paul R. Coyle, Anthony T. Iannacchione

A close look at the Loyalhanna Limestone of southwestern Pennsylvania reveals a complex structural environment. Most exposures of the Loyalhanna occur along Chestnut Ridge and LaurelHill within the Allegheny Mountain Section of the Appalachian Plateaus Province. Because the Loyalhanna is rated as a super-pavement aggregate by the Pennsylvania Department of Transportation and because of its proximity to the population centers of southwestern Pennsylvania, the Loyalhanna has been extensively mined along these prominent anticlinal structures. Geologic and engineering analyses were performed using gas well and core logs, outcrop examinations, underground observations, and mine maps. Strata exposures from both outcrops and quarries were used to construct geologic maps, stereo net, and rose diagram projections so that the Loyalhanna’s structural environment could be understood better. Many of these structural conditions cause ground control problems at local quarries. These problems ranged from small-to-moderate sized rock falls associated with roof jointing to pillar failures associated with dipping discontinuities. Stresses ranged from tensional on structural domes where weathering dominates, to high levels of compression within structural saddles. A greater understanding of these characteristics is a prerequisite to develop engineering controls, such as improved mine layouts, pillar sizes, etc., that lessen miner exposure to these hazards.

By David C. Oyler, Gregory Hasenfus, Gregory M. Molinda

Few studies have specifically measured and documented the large-scale loading behavior and durability of ventilation stoppings to mining induced movements, particularly from longwalls. Ventilation stoppings are more commonly the concern of ventilation engineers, and ventilation stopping response to ground movement has only been documented in an incidental manner. This paper presents the investigations of underground measurements that have been conducted to determine the loading response of stoppings constructed from lightweight aggregate concrete masonry units (CMU). These investigations have produced some interesting results that may prove beneficial, not only for developing and assessing alternative stopping construction techniques, but also for designing and selecting standard construction methods for use in varying mining conditions. For instance, the interface friction that results from wedging a CMU stopping during construction plays a substantial role in its ability to resist both lateral and vertical loads. Although they are not intended for ground support, the study showed that block stoppings can resist vertical loads of at least 2,700 to 3,000 kN. Asymmetric loading of a stopping may result in localized failure of blocks within a stopping, which, depending on the severity, can be a precursor of impending stopping failure. In addition to measurement results and implications, the paper will also present details of field measurement methods used to assess stopping response. Stopping stiffness and material strength characteristics will also be presented.

By Christopher Mark, Anthony T. Iannacchione

Falls of ground continue to be one of the most serious causes of injury to U.S. miners. Of the 256 fatal injuries that occurred in mining between 1996 and 1998, 52 (20%) were caused by falls of ground (Table I). Falls of ground affect some sectors of the mining industry more severely than others. For instance, nearly 40% of the 98 coal mine fatalities between 1996 and 1998 were caused by falls of ground. Underground miners are at much greater risk than surface miners. Nearly half (45 out of 101) of underground mine fatalities were attributed to roof, rib and face falls, while less than 5% of the 155 surface fatalities were caused by falls of highwalls or slopes. Sources of Data All of the injury data examined in this study were derived from MSHA’s Fatal Investigation Reports (www.msha.gov)and the MSHA accident database. Because falls of ground often result in serious injury, MSHA Fatal Alert Bulletins and Fatal Investigation Reports provide a useful snapshot of ground control issues in the mining industry. MSHA requires that mines file a report on every reportable accident that occurs, containing information on the accident’s location, severity, classification, activity, and nature of injury, etc. A short narrative is generally included as well. Accident reports can be searched by many of the above fields. From 1996 to 1998, miners suffered a total of 55,096 injuries, which ranged in severity from death (degree 1) to injuries with no days away from work nor restricted duty (degree 6). Six percent of the total injuries were from falls of ground, including machine accidents where caving rock was coded as the source. As the data in Table II indicate, 98% of all non-fatal fall of ground injuries occurred in underground mines, with underground coal mines accounting for 83% of the total. Table II also shows the distribution non-fatal fall of ground injuries by severity and commodity. The injuries are classified into Lost Time Injuries that resulted in permanent disability (degree 2) or days off work (degrees 3-4), and Injuries Without Lost Time that resulted in no more than restricted duty (degree 5-6). Overall, groundfall injuries appear to be more serious than other types of mining injuries. 65% of all ground fall injuries resulted in lost time compared to 54% of all types of mining injuries.

By A. Dale Marcy, Pamela L. Drake

Workers who perform routine welding tasks are potentially exposed to fume that may contain manganese. Manganese may cause respiratory problems and is implicated in causing the occurrence of Parkinson-like symptoms. In this study, a field colorimetric method for extracting and measuring manganese in welding fume was developed. The method uses ultrasonic extraction with an acidic hydrogen peroxide solution to extract welding fume collected on polyvinyl chloride filters. Commercially available pre-packaged reagents are used to produce a colored solution, created by a reaction of manganese(II) with 1-(2-pyridylazo)-2-naphthol. Absorbance measurements are then made using a portable spectrophotometer. The method detection limit and limit of quantification (LOQ) were 5.2 mg filter-1 and 17 mg filter-1, respectively, with a dynamic range up to 400 mg filter-1. When the results are above the LOQ for the colorimetric method, the manganese masses are equivalent to those measured by the International Organization for Standardization Method 15202-2, which employs a strong acid digestion and analysis using inductively coupled plasma-optical emission spectrometry.

By Peter Swanson, Collin Stewart, Wendell Koontz

A seismic monitoring network has recently been installed in the North Fork Valley coal mining region of western Colorado as part of a NIOSH mine safety technology transfer project with two longwall coal mine operators. Data recorded with this network will be used to characterize mining related and natural seismic activity in the vicinity of the mines and examine potential hazards due to ground shaking near critical structures such as impoundment dams, reservoirs, and steep slopes. Ten triaxial strong-motion accelerometers have been installed on the surface to form the core of a network that covers approximately 250 square kilometers (100 sq. miles) of rugged canyon-mesa terrain. Spread-spectrum radio networks are used to telemeter continuous streams of seismic waveform data to a central location where they are converted to IP data streams and ported to the Internet for processing, archiving, and analysis.

By Patrick J. Coleman, John C. Kerkering

Problem: Mining in the United States remains one of the most hazardous industries, despite significant reductions in fatal injury rates over the last century. Coal mine fatality rates, for example, have dropped almost a thousand fold since their peak in 1908. While incidence rates are very important indicators, lost worktime measures offer an alternative metric for evaluating job safety and health performance. The first objective of this study examined the distributions and summary statistics of all injuries reported to the Mine Safety and Health Administration from 1983 through 2004. Over the period studied (1983 2004), there were 31,515,368 lost workdays associated with mining injuries, for an equivalent of 5,700 person years lost annually. The second objective addressed the problem of comparing safety program performance in mines for situations where denominator data were lacking. By examining the consequences of injuries, comparisons can be made between disparate operations without the need for denominators. Total risk in the form of lost workday sums can help to distinguish between lower and higher risk operations or time periods. Method: Our method was to use a beta distribution to model the losses and to compare underground coal mining to underground metal/nonmetal mining from 2000 to 2004. Results: Our results showed the probability of an injury having 10 or more lost workdays was 0.52 for coal mine cases versus 0.35 for metal/nonmetal mine cases. In addition, a comparison of injuries involving continuous mining machines over 2001 2002 versus 2003 2004 showed that the ratio of average losses in the later period to those in the earlier period was approximately 1.08, suggesting increasing risks for such operations. Discussion: This denominator free safety measure will help the mining industry more effectively identify higher risk operations and more realistically evaluate their safety improvement programs. Impact on Industry: Attention to a variety of metrics concerning the performance of a job safety and health program will enhance industry's ability to manage these programs and reduce risk.

By K. L. Cashdollar, C. K. Man, J. R. Gibbins

Oxyfuel combustion is currently one of the principal technological options being considered for capturing carbon dioxide from pulverised coal power plants. In oxyfuel combustion, coal is burnt in a mixture of recycled flue gases and added oxygen instead of in air. In principle this yields a flue gas containing only carbon dioxide, water vapour and small amounts other impurities. Oxyfuel combustion is superficially similar to combustion in air, but there are inevitable differences. This paper describes ignition tests on pulverised coal suspensions using a suite of coals of different rank and from different countries of origin and over a range of oxygen and coal concentrations of interest for oxyfuel combustion. The ignition tests were carried out using the National Institute for Occupational Safety and Health (NIOSH) 20-litre explosion chamber. The purpose was to determine how easily the various coals ignite and burn in mixtures of O2 and CO2 compared to their combustion in air. The residual char volatile and ash contents for the ignition residues were measured using a thermogravimetric analyser (TGA), allowing Q factors (i.e., enhancement in apparent volatile yield due to higher heating rates and/or heterogeneous reactions) to be determined and compared. An ignition index has been derived from the explosion and char data. This index has been used to rank low volatile coals for ignition propensity in air. The results show that to obtain ignition and combustion comparable to that in air, the oxyfuel O2-CO2 gas mixture must contain over 30% O2. Keywords: CO2 capture, combustion, pyrolysis, oxyfuel.

By William D. Monaghan, Thomas H. Dubaniewicz, Kenneth L. Cashdollar

Emerging laser technologies are quickly gaining acceptance in the industrial workplace. Besides the risk of human exposure, one safety concern with the more intense lasers is the potential for ignition of flammable gases, vapors, dusts, fibers, or flyings often found in hazardous (classified) industrial settings. In underground coal mines, lasers are being considered for remote measurement of explosive methane gas. Current federal safety regulations for underground mines contain no specific guidance for evaluating the safety of optoelectronic components such as diode lasers. The National Institute for Occupational Safety and Health is conducting research to help provide a scientific basis for developing appropriate safety guidelines for optical equipment in the presence of flammable methane gas and/or coal dust. One phase of the study is an experimental evaluation of methane-air ignition by laser heated small particles. Minimum observed igniting powers for laser energy delivered by 200-, 400-, and 800-um core diameter fiber optic cables and directed onto selected targets in methane-air atmospheres were 0.6, L l, and 2.2 W, respectively. Comparisons are made with other ignition phenomena, including heated wires.

By Maria I. De Rosa, Charles D. Litton

The National Institute for Occupational Safety and Health (NIOSH/PRL) conducted a series of large-scale experiments to evaluate the effectiveness of optical flame detectors, photoelectric smoke detectors, and combined ionization and photo­electric smoke detectors for rapidly detecting mining equipment cab fires. The detec­tor alarm times were then used to trigger the discharge of a fire inerting system inside the cab to suppress cab material fires. This paper discusses the types of fire detectors tested, the experiments that Were conducted, and the results that were obtained. Con-" elusions are that rapid detection of equipment cab fires can be achieved to trigger the discharge of a fire inerting system inside the cab to protect the operator in the cab.

By D. R. Tesarik, M. K. Larson, J. P. Dunford, E. G. Zahl

Western coal mines are operating under increasingly challenging ground conditions. Researchers at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health are cooperating with mines to evaluate how these conditions affect mine opening stability and related miner safety. A system was developed to monitor rock and coal stresses during mining of an entire longwall panel. The system was designed to generate data in near real time to evaluate rock behavior in roof strata and the onset of hazardous conditions as overburden stress was redistributed over working entries during gob formation. Computer simulations and in-mine evaluations were used to optimize instrument placement. A prototype packer assembly was designed and tested for installing sensitive instruments in a mine roof. This paper provides background information on the stress monitoring concept and focuses on the development of instrument placement techniques and the prototype packer assembly.

By J. P. Rider

Health surveillance efforts indicate that the development of lung disease and overexposure to respirable dust in underground coal mires continues to afflict mine worker. Results from the most recent round (1992 - 1996) of the Coal Worker's X-ray Surveillance Programs indicate that approximately 8% of the examined miners who had at least 25 years of mining experience were diagnosed with Coal Worker Pneumoconiosis (CWP) (category 1/0+). During the period between 1995-1999, mine operators and MSHA inspectors collected 9968 and 1365 dust samples respectively, from longwall designated occupation (DO) personnel. Analysis of these samples showed that 1970 (20%) of the mine operator samples and 25.8 (19%) of the MSHA samples5 exceeded the 2 mg/m3 dust standard. The continued development of CWP in coal mine workers and the magnitude of respirable dust over-exposures in longwall mining occupations illustrate the need for improved dust control technology on longwalls. Figure 1 illustrates the major longwall dust sources as determined in the early 1990's.4 This article describes the ongoing research to find ways to minimise shearer dust levels as a function of changes in dust control parameters, and research to determine the impact of high air velocities on shield dust entrainment.

By Frank Chase, M. Terry Hoch, George Karabin, Joseph C. Zelanko, Christopher Mark

Pillar recovery continues to be a significant ground control hazard. During the past decade, 10 miners were killed during pillar extraction operations in southern West Virginia. Studies conducted during the past decade have identified a number of “risk factors” that can be used to evaluate pillar extraction plans: •Cut sequence •Final stump •Timber or Mobile Roof Supports •Roof bolting •Intersection span •Depth of cover •Roof quality •Age of workings For each of these factors, rock mechanics science suggests which alternative would be expected to be more risky. For example, numerical models were used to evaluate different cut sequences, and indicated that less roof convergence occurred with the outside lift method than with the Christmas tree in the particular environment simulated. For many of the risk factors, accident statistics confirm the science. One finding was that currently almost 70% of the retreat coal in southern WV is being mined with MRS. In contrast, timber supports were used in 70% of the past decade’s pillaring fatalities. This paper discusses each of the risk factors in turn, presents the relevant accident statistics, and shows how the risk factors can be combined to estimate the overall hazard. It also addresses the use of pillar design to minimize the risk of global stability hazards including squeezes, massive collapses, and bumps.

By G. Esterhuizen, C. Karacan

Methane can be a significant hazard in coal mine longwalling operations and extensive methane mitigation techniques are employed by coal mine operators. Reservoir modeling techniques are used to better understand the liberation and migration of methane from the surrounding rocks towards the mine ventilation system. The caved rock behind the advancing longwall face, known as the gob, can contain high void ratios, providing high permeability flow paths to the methane. The gob is progressively compacted by the weight of the overburden, resulting in a reduction in the void ratio and associated permeability. Estimating the permeability distribution within the gob poses challenges due to its complexity. The authors have developed a new methodology to determine both horizontal and vertical variations in the permeability of the gob. Variations of the permeability in the vertical direction are based on a model of caving and block rotation, which considers the effect of block dimensions and fall height on the void ratio. Gob compaction by the overburden and associated permeability changes are determined from a three-dimensional geo-mechanical model which simulates the gob as a strain hardening granular material. The resulting three-dimensional permeability distribution in the gob is then transferred to a reservoir model. The paper demonstrates the application of the method and shows that reasonable results are obtained when compared to empirical experience and measurements.

By Dana C. Reinke, David K. I Ingram

Researchers at the National Institute for Occupational Safety and Health partnered with the water well industry to develop engi­neering control technologies and training products to address noise exposure at the job site. Noise­induced hearing loss continues to be a problem in the well drilling industry. Research con­ducted by NIOSH found that air rotary drill rigs produce sound levels more than 90 dB(A) over the course of an eight­hour workday. Sounds levels above 90 dB(A), identified during hammer drilling and the hammering of casing, exposes workers to levels that can damage hearing. A typical air rotary drill rig provides no barrier, for noise and dust pro­tection, between the drill’s control panel and the drill stem. The development of a partial cab is the clearest example of NIOSH’s research partnership with the water well industry. NIOSH researchers determined that an engineering noise control to protect the oper­ator at the rig’s control panel would be effective, based on typical work site conditions. Many surface rigs do not have full cabs as a result of the original equipment manufacturer design or the high cost of aftermarket products. Developed as a partial cab, the NIOSH engineer­ing noise control design addressed stakeholders’ needs associated with cost, transport, and worker usage (Figure 1). Field tests found the partial cab effective in reducing sound levels at the rig’s control panel, a typical location for a drill rig operator. Sound levels at the control panel were reduced from 104 to 96 dB(A) (Figure 2). Coupled with continued use of personal protective equipment, such as hear­ing protection devices, the partial cab can help to reduce noise exposure. NIOSH researchers created a CD with informa­tion about noise exposure and the partial cab. Most important to well drilling companies is information on how to construct and attach the partial cab to drill rigs. The CD can be viewed on a standard computer and includes a video of the partial cab in use on a work site. Computer­aided design drawings are included on the CD and provide detail of the cab design as well as information on construction mate­rials and design details. Additionally, the CD provides background infor­mation on noise­induced hearing loss and hearing protection devices to increase knowledge about this occupational health concern. This information can be viewed by all company employees to help promote the partial cab’s importance to workers using the cab. More information on the partial cab noise control technology can be downloaded from www.cdc.gov/ niosh/mining NIOSH researchers also examined the health and safety training needs of workers in the ground water industry. It was quickly realized that most workers learn health and safety on the job and do not attend any sort of formal training. In addition, there is not a lot of time for daily “tailgate talks” or “shop talks” on health and safety issues. As a small business industry, the owner is often operating a drill rig along with his other employees. In general, new employees learn the job in an apprentice style sys­tem. As a result, workers and owners have few opportunities to access uniform health and safety information based upon the job — an outdoor work environment with daily change in work sites. With this information, NIOSH researchers devel­oped two products that deliver health and safety information to fit into the daily work of well drillers. Both are information circulars and are available through download at www.cdc.gov/niosh/mining and the NGWA Web site at www.ngwa.org/publication/ publications.cfm. These circulars are: Water Well Safety Bits. This booklet provides information in a “quick bites” style. It is pre­sented in a magazine format and can be left on

By Gregory M. Molinda

Extremely difficult ground conditions were encountered in the main belt entry in a room and pillar mine in West Virginia. Several generations of supplemental support, including cable bolts, cribbing, and Heintzmann jacks and beams failed to halt roof falls that threatened workers safety and the life of the mine. Polyurethane (PUR) was injected into 27 intersections in the roof and the results were monitored by borehole video camera. The mine had averaged 2-3 falls in the beltway per year and, since the roof injection, no roof falls have occurred. Pre- and post injection monitoring of test holes showed that stability can be achieved without filling all of the existing void spaces. Video logging showed that the project goal of building a beam from 2-6 ft into the roof was successful. Pre-injection monitoring of roof fractures uphole can delineate the zones to target for reinforcement, and avoid pumping PUR into large voids to little effect. Multiple-injection zones can be identified, and the entire intersection drill hole array can be optimized based on knowledge of the fractured zones. In addition, pre-monitoring can prevent excessive hydrofracturing in solid zones. Polyurethane injection is a proven method of rock stabilization in even the weakest, most broken ground. Optimization of the injection design by pre-injection video diagnostics can greatly contribute to the successful and efficient roof stabilization.

By Edward L. McHugh, Charles Sabine, David G. Long

While less than 1% of reported mine accidents are associated with slope stability problems, slope failure accidents were responsible for about 15% of U.S. surface mine fatalities between 1995 and 2003. Small rockfalls, which may involve hand-sized rocks weighing only a few pounds, can cause fatal injuries to workers away from the protection of large machinery. Massive highwall failures containing a million cubic yards of material or more can be fatal even for heavy-equipment operators. As part of an ongoing study at the Spokane Research Laboratory, several remote sensing technologies are being evaluated as tools to assess slope stability and monitor slopes for hazards. An interferometric radar device capable of detecting very small displacements on slopes has been assembled and tested. Radar techniques can provide new tools to augment current methods for monitoring ground control hazards in mines.