Sensing and Monitoring Technologies for Mines and Hazardous Areas. Monitoring and Prediction Technologies

419 Pages·2016·44.43 MB·English

by  Swadesh Chaulya

Sensing and Monitoring
Technologies for Mines and
Hazardous Areas
Sensing and Monitoring
Technologies for Mines
and Hazardous Areas
Monitoring and Prediction Technologies
S.K. Chaulya and G.M. Prasad
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Preface
Theminingindustryisrecognizedasoneofthemostimportantindustriesthe
worldoverasitgoesalongwayinmeetingthecoalandothermineralrequire-
mentsofacountryandprovidesemploymenttoalargenumberofpeople.But
thisindustry,becauseofthenatureofthework,ishighlyhazardousduetovar-
ioustypesofaccidents,whichtakeaheavytollonhumanlife,inflictinjuriesto
severalworkersanddamageminepropertieseveryyear.Rigoroussurveysand
investigationscarriedoutbydifferentresearchershaveconfirmedthatmostof
these accidents can be warded off by taking suitable precautions in real-time,
basedontheregularandsystematicmonitoringoftheprevailingunderground
mining environment, geological features and mechanical soundness—as well
as the integrity of performance ofminingmachinery and equipment.
Sensing the need of the hour the authors have come up with a book entitled
Sensing and Monitoring Technologies for Mines and Hazardous Areas, which will
actasabest-practiceresourceintheminingindustry.Itwillbehighlybeneficial
totheindustryasitpresentsavarietyofdetailsonthelatestsensingandmon-
itoringtechnologiesthatareusinginnovativeideas,alongwithdetailsondig-
italminingandcloudcomputing,whichareessentialforimprovingthesafety
andproductivityofthisindustry.Thebookcontainssevenchapterscoveringa
widerangeofrecentdevelopmentsintheseareasforuseintheminingindustry
and in other hazardousareas.
Chapter 1—Slope Failure Mechanism and Monitoring Techniques: Opencast min-
ing operations involve the removal of huge quantities of overburden. A sub-
stantial increase in the accumulation of waste materials in recent years and
the nonavailability of enough space for their disposal leaves no alternative
buttoincreasetheheightofdumps,givingrisetothedangerofdumpfailure.
Inthecaseoflargeopen-pitmines,steepslopesarepronetofailure.Thesefail-
uresleadtoalossofvaluablehumanlivesaswellasdamagetominingmachin-
ery. Different technologies are available for slope monitoring. After studying
thefeaturesandlimitationsoftheexistingslopemonitoringsystems,itwasfelt
xiii
xiv Preface
thattherewasanecessitytodevelopareliableslope stability monitoringand
predictionsystembyusingasolarpower-based,long-rangewirelesssensornet-
workforthecontinuousmonitoringofdifferentprevailingparametersofslope
stability. Tomeetthisrequirement,aslopefailuremonitoringandprediction
systemhasbeendevelopedbytheauthorsusingawirelesssensornetwork.The
systemcontinuouslymonitorsvariousparameterspertainingtoslopestability
and provides early warning of impending slope failure on the basis of multi-
parameter prediction models. Besides mining, this technology is applicable
formonitoringthestabilityofdamslopesandsteepslopesalongrailwaytracks
androadsinhillyterrains.Thechapterdescribesthedetailsoftheslopestability
mechanism,parameterseffectingslopefailureanditstriggeringaspects,mon-
itoringsystems,predictivesoftware,laboratoryexperimentsforcalibratinggeo-
sensors and fieldinstallation of thedeveloped system.
Chapter2—MineTransportSurveillanceandProductionManagementSystem:Mine
transportsurveillanceandproductionmanagementsystemhasbeendesigned
withtheaimofcheckingfortheoverloadingofmineralsontrucksordumpers
andtheefficientremovalofmineralsfromaminesite,whileatthesametime
stopping the illicit transportation of minerals through unauthorized routes.
The system consists of five modules: the weighbridge automation module
for the unmanned check of mineral overloading on trucks or dumpers; the
vehicletrackingandproductionmonitoringmoduleforkeepingacontinuous
watchonthevehiclesontransportationroutes,andthemonitoringofproduc-
tion,aswellasprovidingadviceontheoptimumuseofshovels,dumpersand
otherauxiliaryequipmentbyminimizingtheiridlingtime;closecircuittelevi-
sioncamerasforkeepingthesurroundingsunderconstantsurveillance,partic-
ularlytowatchvehiclescarryingminerals;aperipherysurveillancemodulefor
detectingtheintrusionofvehiclesthathavetheintentiontoillegallytransport
minerals through unauthorized routes; and a centralized monitoring station
foroverseeingalltheactivitiesoftransportsurveillanceandproductionmon-
itoring.Thissystemwoulddefinitelyprovetobeaboontotheminingindustry
asitisquiteeffectiveinpreventingfinanciallossduetomineraltheft,whileat
the same time improving the efficiency of the smooth dispatch of minerals
throughthe optimum use ofshovels and dumpers.
Chapter3—GasSensorsforUndergroundMinesandHazardousAreas:Somestrata
gasesthatgetmixedwithundergroundmineatmospheresarehighlypoisonous
andafewaredangerouslyflammable.Variousgasesarealsoformedinunder-
ground mines due to chemical reactions such as the spontaneous heating of
coal, etc. The concentration of mine gases found at any time and location
mayvaryduetodifferentfactorslikediffusion,turbulentdispersionandleak-
ageinsubsurfaceventilation systems. Therefore,itisnecessarytodeploysen-
sorstomonitorandmeasuretoxicandflammablegasconcentrationlevelsin
Preface xv
the subsurface atmosphere for the safety of underground miners as well as
mines themselves. Each sensor has its own advantages and limitations. Some
sensorsarebetterforsensingtoxicgases,whereasothersaresuitableforcom-
bustible gasdetection.Thischapterpresentstheprinciplesand application of
different types of gas sensors, procedures for sensor deployment and the cali-
bration and interpretation of sensor data.
Chapter 4—Local Methane Detection and Power Cut-Off System: Local methane
detectionandpowercut-offsystemforundergroundmineshavebeendesigned
toaccomplishthecontinuousmonitoringofmethanegasconcentration.They
consistofsubunits,namelyanintakefan,aninfraredmethanesensor,aloud
audio alarm generator, a visual display screen, an auto power cut-off relay, a
detachablebattery,aremotereadoutfacilityandamicro-controller.Themin-
ingindustrywillbenefithighlyfromthisdevelopmentasitpreventsminedisas-
terscausedbymethaneexplosionsthroughcuttingoffthepowersupplywhen
methaneconcentrationexceedsthepermissiblelimit,andatthesametimetrig-
gering alarms that help in the evacuation of miners and machinery from the
dangerzone,whichresultsinthesavingofvaluablehumanlivesaswellasmine
property.
Chapter5—IntegratedMineEnvironmentandStrataConditionMonitoringSystem:
Undergroundcoalminesarewellrecognizedashazardousareasthatareprone
toaccidentscausedbyrooffall,andthecollapseofgallerysides,gaspoisoning,
gasandcoaldustexplosions,etc.Besidesthesehazards,theworkingenviron-
mentinside amine often becomes uncomfortabledue toadeficiencyofoxy-
gen;thesuddenappearanceoftoxic,inflammableandunpleasantgases;andan
increaseintemperatureandexcesshumidity.Tocopewiththeseproblems,the
miningindustryisinneedofsuitablesensorsthatassessdifferentunderground
situationsandgivewarningofimpendingdangers,andthatallowforthetaking
ofproactiveactions.Thischaptercontainsdetailsabouttheintegratedenviron-
mentandstratamonitoringsystemdevelopedbytheauthorsofthisbook.This
systemiscapableofmonitoringsevengases(methane,carbonmonoxide,car-
bon dioxide, oxygen, nitrogen dioxide, sulfur dioxide, and hydrogen sulfide)
andotherenvironmentalparameterslikeairvelocity,temperatureandhumid-
ity.Itcanalsobeusedformonitoringthreestrataparameters(theloadofthe
roofataparticularpoint,theconvergenceoftheroofandthepressureonpil-
lars) and different micro-seismic events that generally occur in mines mainly
due to blasting and roof fracturing. The uniqueness of this system is that it
accommodates 14 different sensors for monitoringrespective parameters.
Chapter6—FormationofDigitalMineUsingtheInternetofThings:Adigitalmineisa
simulatedversionofactualminingconditionsonacomputerscreen.Thecondi-
tionofvirtualrealityiscreatedthroughabasisontheInternetofThings(IoT),
xvi Preface
with the aim of getting a vivid idea of prevailing underground situations and
the monitoring of various mining parameters. These act as essential inputs for
real-time decision making and the proper management of various mining
activitiesincludingminingoperations,lookingintosafetyaspects,maintenance
of congenial mine environments, rescue operation of trapped miners,
restoration of mining conditions after an accident, the training of miners, etc.
The IoT provides an infrastructure for sensing, collecting, processing and
application of acquired information with the help of sensors, actuators, radio
frequency identification (RFID) devices, CCTV, gateway, 3D display units, etc.
Thus, digital mines open up a new scope for enhancing production, ensuring
the safety of mines and miners, and providing safe working environments
inmines.
Chapter7—ApplicationofCloudComputingTechnologyinMiningIndustry:Cloud
computing systems, which are the latest versions of computing models avail-
able,havepracticallyrevolutionizedtheinformationtechnology.Theydistin-
guish themselves from other computing paradigms due to their unique
characteristics suchastheability tohandlemassive data,thepowerofvirtua-
lization,scalability,elasticity,agility,resourcepoolingcapability,anddepend-
ablesecurity.Moreover,theyareverycost-effectiveandusableforindividualas
well as industries. The mining industry, which is facing several challenges of
variedcomplexities,canreapthebenefitsofthistechnologyindifferentareas
such as mine automation, knowledge sharing, process improvement, safety
management,equipmentconditionmonitoring,environmentalimpactassess-
mentand management,environmental modeling, thetrackingofminersand
moveableminingmachinery,assetmanagement,andefficiencyimprovement
inallfacetsofminingactivitiesandremoteoperations.Cloudcomputingtech-
nologywithinashortperiodhasalreadyshownthepotentialforbecominga
majordriverofgrowth forseveral industries. Itcan helpwithenhancingpro-
ductionaswellasincreasingsafetyandtherebybringingeconomicbenefitsto
the mining industry. This chapter narrates in detail about cloud computing
technology including its deploymentmodels, characteristics, implementation
status and application in mines.
Thebookwillbeimmenselyusefulforthescientists,professionals,geologists,
geotechnical engineers, mining engineers, electronics and communication
engineers, researchers, students, etc., who are closely associated with these
subjects in connection with their work, research, and studies. The book will
alsobeusefulforpracticingengineersasitcoverscomprehensiveinformation
on advanced technologies as well as the study of different types of sensors
and their application for the monitoring of various mining activities, which
are important for the cost-effective deployment of systems in the field used
to minimize mining hazards, and enhance safety and productivity. Further,
Preface xvii
the book contains complete details of the circuit diagrams for different sys-
tems developed by the authors so that the researchers and manufacturers
working in the field may make use of these technologies for several
applications.
Dr. S.K. Chaulya
Dhanbad,India
Dr. G.M. Prasad
Dhanbad,India
Acknowledgments
Deep gratitude is expressed by the authors to Dr. Girish Sahni, DirectorGen-
eral, Council of Scientific and Industrial Research (CSIR), New Delhi, India
andDr.PradeepK.Singh,Director,CSIR-CentralInstituteofMiningandFuel
Research (CIMFR), Dhanbad, India for their constant valuable guidance and
alsoforprovidingfacilitiestocarryoutthevariousresearchanddevelopmental
projects through which different sensing and monitoring devices for applica-
tioninminesandotherhazardousareashavebeendevelopedbytheauthors.
MarianaKu€hlLeme,EditorialProjectManagerandAnushaSambamoorthy,Pro-
ductionProjectManager,ElsevierS&TBooksdeservesincerethanksfortheirkind
helpandguidanceinpreparationofthemanuscriptofthebook.Authorsarealso
thankfultoRaquelZanol,AcquisitionsEditor,ElsevierS&TBooksforevaluating
thebookproposalandprovidingvaluablesuggestionstostructurecontentofthe
book.SpecialthanksarealsodueforAnaClaudiaAbadGarcia,Intern(Editorial
Project Manager) and Victoria Pearson, Elsevier S&T Books for designing an
attractivecoverpageofthebook.TheauthorsalsothankElsevierforpublishing
thebook.
TheauthorsarealsothankfultoMr.K.L.Bandyopadhyay,RetiredScientistof
CSIR-CentralInstituteofMiningandFuelResearch(CIMFR),Dhanbad,India
foreditingthemanuscriptandprovidingvaluablesuggestionswithoutwhich
thebookwouldhavefailedtoseethelightoftheday.Theauthorsalsoexpress
thankstotheanonymousreviewersforevaluatingthebookproposalandpro-
viding valuablesuggestions.
The help extended by Mr. B.M. Baveja, Senior Director, Dr. Tulika Pandey,
Director, Mr. Kamlesh Kumar, Scientist, and Mrs. Hemlata Gupta, Scientist,
Department of Electronics and Information Technology (DeitY), Ministry of
Communication and Information Technology, Government of India, New
DelhibyfundingtheR&Dprojectsrelatedtomonitoringandsensingishighly
acknowledged.AuthorsarealsogratefultoCoalIndiaLimitedforgrantingfield
trialpermissionintheirmines.TheyarealsoindebtedtoMr.DebasishSarkar,
General Manager and Mr. Jayanta Das, Mine Manager of North Eastern xix
xx Acknowledgments
Coalfields,Margherita,Assam,Indiaforprovidingtheirlogisticsupportduring
field trials of the developed systems intheirmines.
TheauthorstakethisopportunitytoconveytheirheartythankstoDr.P.PalRoy,
Mr. A.K. Ghosh, Dr. L.K. Bandyopadhyay, Dr. Rajendra Singh, Dr. B. Kumar,
Dr. C.N. Ghosh, Dr. G. Banerjee, Dr. D. Basak, Dr. R.K. Viswakarma,
Dr. N.K. Verma, Dr. S.K. Ray, Dr. R.S. Singh, Dr. R.V.K. Singh, Dr. V.K. Singh,
Dr. K.B. Singh, Dr. A. Prakash, Dr. A.K. Bandyopadhyay, Dr. D. Kumbhakar,
Dr.V.K.Kalyani,Dr.R.K.Tiwary,Dr.S.R.K.Rao,Mr.AmarNath,Dr.P.K.Mishra,
Dr.A.K.SinghandDr.D.MohantyofCSIR-CIMFR,Dhanbad,India;Dr.S.Rath
of CSIR-Institute of Mineral and Material Technology, Bhubaneswar, India;
Dr.P.C.Sarmah,Dr.P.SaikiaandMr.K.BuragohainofCSIR-NorthEastInstitute
of Science and Technology, Jorhat, India; Dr. S.N. Maity of CSIR-Central
MechanicalEngineeringResearchLaboratory,Durgapur,India;Mr.H.S.Dadhwal
andMr.G.S.DadhwalofM/sSafeInstruments,Mohali;Prof.AsishMukherjee
and Dr.SudipMisraofIndianInstitute ofTechnology,Kharagpur, India;Prof.
T.N.Singh,IndianInstituteofTechnology,Bombay,India;Prof.B.K.Shrivastava
of Indian Institute of Technology, Banaras Hindu University, Varanasi, India;
Prof.V.Kumar,IndianSchoolofMines,Dhanbad,India;Prof.ChandanGhosh
ofNationalInstituteofDisasterManagement,NewDelhi,India;Prof.B.B.Dhar
andDr.A.Sinha,Ex-directors,CSIR-CIMFR,Dhanbad,India;Prof.U.B.Desai,
Director, Indian Institute of Information Technology, Hyderabad; Mr. Rahul
Guha, Directorate General of Mines Safety, Dhanbad, India and other expert
membersfortheirvaluablesuggestionsandencouragementduringthedevelop-
mentofdevicesbytheauthors.
The cooperation extended by the Chairman and Director (Technical) of Coal
India Limited, Kolkata and Chairman-cum-Managing Directors of Central
MinePlanningandDesignInstituteLimited,CentralCoalfieldsLimited,Bharat
Coking Coal Limited, Eastern Coalfields Limited, Mahanadi Coalfields Lim-
ited, Northern Coalfields Limited, Western Coalfields Limited, South Eastern
Coalfields Limited and Singareni Collieries Company Limited, India will be
ever remembered by the authors for partially funding the projects related to
the sensing and monitoring technologies and rendering their logistic support
during the implementation of the developed devices inthe fields.
TheauthorsarehighlyobligedtoMr.BhogeshKumar,Mr.ShashiKumarShukla,
Mr.BireshKumar,Mr.PrabhatRanjan,Mr.SubhadeepDutta,Mr.AnishKumar,
Mr.AbhishekKumar,Mr.T.M.GiriKingson,Mr.RanjeetMandal,Mr.Rajkumar
Prasad Verma, Mr. Dinesh Kumar, Mr. Raj Kumar and Md. Shanwaz Ansari
whoconstantlyworkedhardwiththeauthorsforthedevelopmentofdifferent
sensing and monitoring devices during their tenure as Project Assistants of
CSIR-CIMFR,Dhanbad,Indiaindifferentministry-sponsoredprojects.