2014 Electrical Engineering Safety Seminar 5 & 6 November at Sydney's Waterview Park

1. www.centennialcoal.com.au
Booster Fans
Angus Place Colliery
BJ Cutting
Manager of Electrical Engineering
Angus Place

2. Centennial Angus Place
2
Scone
Rylstone
Mudgee
Muswellbrook
Singleton
Maitland
Newcastle
Lithgow
Gosford
SYDNEY
Katoomba
Berrima
Wollongong
Port Kembla
Kiama
Moss Vale
Angus Place

3. Introduction
3
•
Mine established in 1978
•
Mining the Lithgow seam
•
No history of methane or spontaneous combustion in Lithgow Seam
•
Currently developing the Angus Place East Area which is an expansion of Angus Place workings to 2031
•
Planned production averages 3.5 Mtpa with longwall extraction
•
New Angus Place East ventilation facilities currently being constructed.
•
Shaft No.1 due for commissioning in January 2015
•
Current ventilation into Angus Place East was not sufficient to support anticipated mining operations.

4. Process
4
•
It was identified that a Booster Fan would be required to provide adequate ventilation to the Angus Place East area until the completion of the new ventilation shaft no.1.
•
Angus Place investigated what fan options where available within the industry that would suit the Angus Place short term application. (6-9 months)
•
Identified 5 possible locations where the Booster Fans could be installed.
•
Ventsim software was used to model the 5 selected Booster Fan locations.
•
The decision was then made to install the Booster Fan in an intake airway not a return airway like other Booster Fan installations.

5. Booster Fan Locations Investigated
5
1.
At the intake panel entry of 910 (preferred option)
2.
In the return outbye in 910 panel
3.
At the 910 install road
4.
Inbye 910N intake
5.
Inbye 910N return
1
2
3
5
4

6. Mine Plan
6
Current Angus Place Workings
Future Angus Place East Workings
New Upcast and Downcast Shafts
Booster Fan Location

7. Process
•
Angus Place conducted a risk assessment to identify the risks associated with a booster fan installation.
•
Key Outcomes from the Risk Assessment.
–
Legislative requirements.(Design and Item Registration)
–
Organise meetings with key stakeholders.
•
Department of Trade and Investment
•
Fan Manufacturers
–
Develop a functional specification for the operation of the Booster Fan.
–
Short timeframe for the Booster Fan Installation.
–
Additional work required outside the Booster Fan scope.
(ventilation devices)
•
Visited other mining operations with in service booster fan installations to assist with the equipment selection process.
7

8. Meeting with Department of Trade and Investment
•
To obtain an understanding of how the department viewed a Booster Fan Installation in an intake airway and to make the process as smooth as possible.
–
Could we treat it like a conveyor installation? Not a Booster Fan installation.
–
Was there a requirement to apply for Design and Item Registration?
–
Was it a High Risk Activity?
–
How would the department see the registration process moving forward.
–
Was there anything that they could see being a show stopper?
8

9. Equipment Selection
9
•
3 x 110 kW Clemcorp axial fans in parallel
•
Ability to run either 2 or 3 fans in parallel due to fitment of self closing doors in each fan duct
–
Eliminates recirculation in the event of a single fan failure
•Fans used extensively in underground metalliferous mines as booster fans.
•Nickel Brass alloy impellers and mild steel ducting.
•Modular design ensures quick and simple installation.

10. Existing Fan Installation in a Metaliferous Mine
10

11. Brass Nickel Impeller
11

12. Positives - Preferred Option
•
Reduced risk compared to an installation in a return airway.
•Legislation requirements.
–Less departmental requirements ? (was the thought process)
•Easier installation
–Access restricted in the belt road.
–Parallel Installation.
–No loss of production.
•Reduced pressure across the coffin seal.
12

13. Negatives - Preferred Option
•
Restricted access around Booster Fans
–
Vehicle access through double ventilation doors.
–
Process to get larger pieces of equipment through double doors.
–
People and machine movement around and past Booster Fans.
•Airborne dust
– Along 910 travelling road.
– Migrating into 1000 district production units.
13

14. Functional Specification
•
If the main vent fan stops the booster fan is to stop immediately.
•
If any fan selected to run stops, all other booster fans stop.
•
If the booster fans stop the C910 conveyor is to be inhibited.
•
Environmental monitoring of CH4 and CO, if levels are detected above the pre-set values all booster fans stop.
•
Any failure of ventilation inbye or outbye of the booster fan installation, will cause all booster fans to stop.
–
Stopping Failure
–
Access or by-pass doors not in their correct position.
•
If ventilation pressures are outside of the intended tolerances all booster fan are to stop.
•
If the booster fans stop all power inbye of booster fans is turned off.
14

15. Functional Safety Assessment
15

16. Booster Fan Setup
•
Bypass Doors open if the Booster Fans are stopped
–
Proximity sensors to monitor position of bypass doors and machine access doors.
•
Vibration and Temperature monitoring on all fans
•
CO and CH4 monitoring inbye and outbye of fans
•
Differential pressure monitoring across
–
Fan Bulkhead
–
Coffin Seal
–
19C/T 303 District
•
Fans set to trip on any one failure of system components
•
Monitoring alarms in control room
16

17. Booster Fan Setup
17
BYPASS DOORS
D
D
Belt Road
Return Road
PNEUMATIC ACCESS DOORS
COFFIN SEAL

18. Booster Fan Monitoring
18
PROXIMITY SENSORS
D
D
Belt Road
Return Road
PRESSURE MONITORING
CO & CH4 MONITORING

19. Fans Installed at Angus Place
19

20. Bulkhead Self Closing Fan Doors
20

21. Bypass Doors & Pneumatic Machine Access Doors
21
PNEUMATIC MACHINES ACCESS DOORS
VENTILATION BYPASS DOORS

22. Potential Hazards Identified in Risk Assessment
22
•
Booster Fan not turning off when Main Fan stops
•
Inability to conduct maintenance caused by insufficient access around Booster Fan
•
Fire on Booster Fan
•
Damage to Bypass Doors
•
Insufficient air reaching Booster Fan due to failure of Ventilation Control Device outbye of 910N
•
Complete failure of Booster Fan
•
Partial failure of Booster Fan
•
Increased dust caused by increased air velocity in 910N
•
Noise generated from booster fans

23. Citect Display / Remote Monitoring
23

24. Booster Fan Starter
24

25. Booster Fan Starter
25

26. Commissioning
26
Electrical Commissioning Sheet
0 Fans
1 Fan
2 Fans
3 Fans
Settings (3 Fans Opperational)
Reading
Expected
Actual
Expected
Actual
Expected
Actual
Expected
Actual
Setting Type
Setting Value
Bypass Doors
Open
Open
Closed
Closed
Closed
Closed
Closed
Closed
Access Door 1 (outbye)
Closed
Closed
Closed
Closed
Closed
Closed
1 of 3 Closed
Closed
Access Door 2 (middle)
Open
Open
Open
Open
Open
Open
Open
Access Door 3 (inbye)
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Coffin Seal Pressure
1148
1270
780
784
350
490
Trip/Alarm Low
Alarm/Trip High
300/400
900/1000
19 c/t, 303 Stopping Pressure
1727
1750
1500
1409
1255
1240
Trip/Alarm Low
Alarm/Trip High
400/500
1600/1700
Booster Fan Pressure
0
0
890
1240
2010
2020
Trip/Alarm Low
Alarm/Trip High
900/1000
2400/2500
Gas Sensor- CO inbye
0
0.2
0
0.2
0
0.2
Alarm
Trip
15 ppm
25ppm
Gas Sensor- CO outbye
0
0.2
0
0.2
0
0.2
Alarm
Trip
15 ppm
25ppm
Gas Sensor- CH4 inbye
0
0
0
0
0
0
Alarm
Trip
0.25%
0.50%
Gas Sensor- CH4 outbye
0
0
0
0
0
0
Alarm
Trip
0.25%
0.50%
Bypass Timer (minutes for pressurisation)
5 mins
5 mins
5 mins
5 mins
Timer Values (T1/T2)
6 mins
6 mins
Fan 1
Axial Vibration Sensor
1.01 mm/s
Alarm
Trip
6 mm/s
8 mm/s
Radial Vibration Sensor
1.02 mm/s
Alarm
Trip
6 mm/s
8 mm/s
DE Bearing Temperature Sensor
41 ᵒC
Alarm
Trip
60 ᵒC
80 ᵒC
NDE Bearing Temperature Sensor
45 ᵒC
Alarm
Trip
60 ᵒC
80 ᵒC
Winding Temperature Sensor 1
61 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Winding Temperature Sensor 2
62 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Winding Temperature Sensor 3
60 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Fan 2
Axial Vibration Sensor
1.02 mm/s
Alarm
Trip
6 mm/s
8 mm/s
Radial Vibration Sensor
0.90 mm/s
Alarm
Trip
6 mm/s
8 mm/s
DE Bearing Temperature Sensor
44 ᵒC
Alarm
Trip
60 ᵒC
80 ᵒC
NDE Bearing Temperature Sensor
44 ᵒC
Alarm
Trip
60 ᵒC
80 ᵒC
Winding Temperature Sensor 1
59 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Winding Temperature Sensor 2
60 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Winding Temperature Sensor 3
60 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Fan 3
Axial Vibration Sensor
1.03 mm/s
Alarm
Trip
6 mm/s
8 mm/s
Radial Vibration Sensor
0.99 mm/s
Alarm
Trip
6 mm/s
8 mm/s
DE Bearing Temperature Sensor
42 ᵒC
Alarm
Trip
60 ᵒC
80 ᵒC
NDE Bearing Temperature Sensor
44 ᵒC
Alarm
Trip
60 ᵒC
80 ᵒC
Winding Temperature Sensor 1
61 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Winding Temperature Sensor 2
60 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Winding Temperature Sensor 3
62 ᵒC
Alarm
Trip
85 ᵒC
120 ᵒC
Noise Level (dBA) (Starter/Fan Guarding)
83/95
83/95

27. Ventilation Survey
27
LocationVentsim QVensim PMeasured VMeasured QMeasured PVentsim QVensim PMeasured VMeasured QMeasured PVentsim QVensim PMeasured VMeasured QMeasured P910N 4 - 6 C/T14.9865113962.78771600912250910N 16 - 17C/T166169059750 @ 17 C/T729704.673.611108513624.8577.61260910N 35-36 C/T15.5498345100 @ 35 C/T581173.655.8125691653.960.45150910 0-1C/T 3 hdg15.3678118874895.990.6241026.295.232910N Regulator9.68278.7929.894.081041096910N Coffin Seal9114812707780770535049082918901290111201020201900 7 - 8 C/T15.517146071.3400 @ 8C/t663954.163.591350603203.8559.7135270LW Face343229303 19C/T172717501500140012551240Main Fan220223227303 regulator77960970740700No Fans Bypass Open2 Fans Running3 Fans RunningFan Bulkhead (D/D Closed) Fan Bulkhead (D/D Open)

28. Item Registration
28

29. Plant Registration - Exemption
29

30. Start-up Sequence
30

31. Acknowledgements
•
Shane McClure & Scott Wyborn - Centennial Coal.
•
Clemcorp Australia.
•Simon Fulton & Grant Waring – ATF.
•Mike Taylor – Advitech.
•Marcus Punch.
31

32. www.centennialcoal.com.au
Thank You