Hazard Identification and Risk Assessment for the Use of Booster Fans in Underground Coal Mines
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1 Hazard Identification and Risk Assessment for the Use of Booster Fans in Underground Coal Mines Felipe Calizaya Michael G. Nelson Mahesh Shriwas Feb 26, 2013
2 Outline Introduction Booster Fans in U/G Coal Mines Hazard Identification and Risk Assessment Risk Assessment Tools Conclusions
3 Introduction Booster Fan An underground fan installed in a main airway and sized to handle the quantity of air needed in a section Installed in a permanent bulkhead and equipped with a set of airlock doors and fan monitors Can be used to create safer work conditions and allow the extraction of minerals from greater depths.
4 Merits and Demerits of Booster Fan Merits Reduces main fan pressure Reduces air leakages Reduces ventilation cost. Demerits Increases possibility of uncontrolled recirculation Increases propensity of fire Increases build-up of contaminants.
5 Booster Fan Installation Details
6 Custom Built Centrifugal Fan
7 Booster Fans in U/G Coal Mines Sample Coal Mine Ventilated by exhaust system of ventilation Has one long-wall section and two continuous miner sections Has one main surface fan Has one main intake and two smaller intake airways Has a good scope for the use of booster fan.
8 Mine Ventilation Network Flow requirement Mine Ventilation Network
9 Mine Ventilation Network Requirement of Air C M Section 1: 33.0 m 3 /s CM Section 2: 21.0 m 3 /s Longwall Face : 47.0 m 3 /s Bleeder System: 21.0m 3 /s Sealed Area: 66.0 m 3 /s 188 m 3 /s Statement of the Problem Mine needs efficient and safe ventilation system to fulfill the requirements of air at the different sections of a mine while considering leakages It requires either single fan system or two fans system to fulfill the requirements of air.
10 Solutions to the Problem Simulation Results Fan Duty Pressure (Pa) Quantity (m 3 /s) Air Power (kw) Total Air Power (kw) 1. Single Fan System Main Fan Only Two Fan System Main Fan Booster Fan
11 Installation and Commissioning Requires bypass drift, or widening of existing drifts, and installation of airlock doors Needs enough space to house the fan assembly, man doors, and condition monitoring components Needs manufacturer involvement during fan installation. Evaluation Standards Vibration (alarm): 5.5 mm/s Bearing- Motor temperature: 85 ºC Fan duty: 5% of designed values
12 Hazards Identification A hazard is anything that has potential to cause harm to miners or damage to property Inventory of Hazards: Electrical: fan, monitoring malfunction Mechanical: moving parts Chemical: fires, spontaneous combustion Pressure: stuck in airlock door.
13 Hazards Identification Unwanted Events: Power failure to mine Erroneous monitoring of read-outs Equipment failure Fires and explosions Recirculation of air contaminants
14 Risk Assessment Risk is a product of likelihood of occurrence and consequences of undesired event Risk Analysis is the process by which risks are identified, examined and their magnitudes are determined Risk Assessment is the process by which the outcome of risk analysis is compared to its risk acceptance criteria
15 Principles of Risk Assessment Identify the Risks Monitor Performance Assess the Risks Monitor for Change Decide to Eliminate Decide to Mitigate Decide to Tolerate Take Action
16 Risk Matrix Categories of harm severity Catastrophic: Multiple deaths Critical: One death or multiple severe injuries Moderate: One to three severe injuries Minor: One severe injury or multiple minor injuries Insignificant: One minor injury Categories of harm probability Most Certain: Occurs once or twice a year Likely: Occurs less than once in year or may recur once in 5 years Possible: Has occurred or may recur in 10 years Unlikely: May occur in 20 years Rare: Has never happened
17 Likelihood 1 Insignificant Risk Matrix 2 Minor 3 Moderate Risk Rating 4 Major 5 Catastrophic 5. Most Certain Likely Possible Unlikely Rare Risk Rating Legends Guidelines for Risk matrix 15 to 25 (Ex): Extreme Eliminate or avoid and implement action plan 9 to 12 (H): High Proactively manage 4 to 8 (M): Medium Actively manage 1 to 3 (L): Low Monitor and manage
18 Risk Assessment Tools 1. Job Safety Analysis 2. Bow Tie Analysis 3. Workplace Risk Assessment and Control 4. Failure Mode Effect Analysis 5. Fault Tree Analysis 6. Event Tree Analysis 7. Hazards and Operability Studies
19 Workplace Risks Assessment and Control (WRAC) 1. A broad-brush risk ranking approach 2. Breaks down the mining process with potential hazard 3. Involves a flow chart with potential hazard identification 4. Accomplished with the use of JSA and SOPs 5. Identifies potential unwanted events 6. Includes the likelihood and consequences of each stage 7. Includes controls and recommended measures
20 WRAC (Design Stage) Steps in process Unwanted Events Current Control Measures L C R Recommended Measures Oversizing and poor location of booster Fan Recirculation and fire Use VnetPc software to size and site the fan Check for recirculation before implement the design Failure to design good monitoring system Failure to good design airlock doors and bulkhead Undetected fire and recirculation Recirculation, fails to open airlock door Manual sampling of air Airlock doors and bulkhead tested for its stability Follow the good practice as adopted in other country Follow the good practice as adopted in other country
21 WRAC (Installation & Commissioning) Steps in Process Failure to measure temperature and vibrations Misalignment of fan shafts Unwanted Events Recirculation, fire, damage to foundation Excessive vibration of fan parts Current Control Measures Fan monitoring system Follow manufacturers specifications L C R Recommended Measures Manual check and maintenance Alignment must be tested manually Testing of Fan Failure to follow SOP s People caught in between moving parts Fan not running well Barriers and screens around the Fan Safety screen, good illumination Training Refresher training
22 WRAC (Operation Stage) Steps in Process Mechanical Electrical Fault Unwanted Events Failure of interlocking Current Control Measures Main and booster fans in same circuit Chemical Fire Good house keeping Chemical Chemical Chemical Buildup of mine gases Spontaneous combustion Dust buildup on blades Through flow ventilation Shotcreting of the roof, floor and sides of roadways Water spraying during cutting and crushing L C R Recommended Measures Independent power source for booster fan Good monitoring, firefighting equipment must be in place Construction quality control of vent. devices Booster fan located in overlying or underlying strata Scheduled Maintenance of diesel units (250 hrs)
23 Interpretation of Outcomes of WRAC All the inventory of hazards are identified during design installation and operation stage Major hazards would be controlled by recommended control measures Fire and recirculation are major hazards and need special attention to prevent them. Interlocking between main and booster fan must be tested and maintained in order
24 Failure Mode Effect Analysis (FMEA) Applicable to potential failure of subsystems Failure modes of individual items are determined Effect on other items and system are recognized Risk rank of failure item are determined Criticality is calculated (severity X probability) Control measures are prioritized based on criticality Bottom-up evaluation technique Qualitative and quantitative techniques
25 FMEA of A Sample Problem Failure Mode (Electrical) Other Effect on L C R Controls System 1. Failure of monitoring devices a) Undetected environmental conditions Undetected spontaneous heating and fire Redundant sensors recalibration maintenance b) Undetected vibration and temperature of motor bearings Overheating of motor source of ignition Provide uninterrupted power supply 2. Failure of power to mine site Main, booster and bleeder fans are stopped Whole ventilation system is collapsed Generator set with standby fan L- Likelihood C- Consequences R- Criticality or Risk rank
26 FMEA of A Sample Problems Failure Mode (Mechanical) 1. Failure of main fan Effect on L C R Controls Other Main fan is stopped System Ventilation is deteriorated Stop booster fan and downstream equipment 2. Failure of booster Fan Booster fan is stopped Ventilation is deteriorated Open airlock doors, stop downstream equipment 3. Failure of airlock doors Flow of air is stopped Ventilation is short-circuited Stop downside equipment Guide miners to refuge chamber
27 Interpretation of FMEA Outcome Failure of power to the mine site is an extreme risk Failure of the monitoring system is a high risk Failure of the main fan is a high risk Failure of the booster fan is manageable Failure of and airlock door is manageable; however, it can induce recirculation of air contaminants
28 Conclusions Risk Assessment is an integral part of booster fan operation in underground coal mines in others part of world Fire and flow recirculation are two major hazards associated with the operation of booster fans RA reduces the impact of undesired events, if known early Risk matrix information prioritizes the risks FMEA is used to analyze risks of system components WRAC is used to analyze risks by JSA and SOP RA is used during design, installation & operation stages
29 Future Work Fault Tree Analysis will be applied to hazards identified in the case study to determine main contributing factors Attempts will be made to collect field data associated with main and booster fan to quantify the risk The outcomes produced by WRAC and FMEA will be refined by applying a revised risk matrix Major hazards and risks associated with the operation of booster fans will be summarized and used to develop an operation protocol
30 Thank You
31 Questions?
32 Booster Fan Installation Details To Tail Gate Man Doors Bulkhead Return Booster Fan Airlock Doors Intake Fan and Environmental Monitors Tube Bundle Methane Carbon Monoxide Manometer Smoke Delta Pressure
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