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By Thomas J. Fisher, Christopher C. Jobes, Edward F. Fries

This report (Software Safety 2.2) is the third in a nine-part series of recommendations addressing the functional safety of processor-controlled mining equipment. It is part of a risk-based system safety process encompassing hardware, software, humans, and the operating environment for the equipment’s life cycle. Figure 1 shows a safety framework containing these recommendations. The reports in this series address the various life cycle stages of inception, design, approval and certification, commissioning, operation, maintenance, and decommissioning. These recommendations were developed as a joint project between the National Institute for Occupational Safety and Health and the Mine Safety and Health Administration. They are intended or use by mining companies, original equipment manufacturers, and aftermarket suppliers to these mining companies. Users of these reports are expected to consider the set in total during the design cycle. • 1.0 Safety Introduction.—This is an introductory report for the general mining industry. It provides basic system/software safety concepts, discusses the need for mining to address the functional safety of programmable electronics (PE), and includes the benefits of implementing a system/software safety program. • 2.1 System Safety and 2.2 Software Safety.—These reports draw heavily from International Electrotechnical Commission (IEC) standard IEC 61508 [IEC 1998a,b,c,d,e,f,g] and other standards. The scope is “surface and underground safety-related mining systems employing embedded, networked, and non networked programmable electronics.” System safety seeks to design safety into all phases of the entire system. Software is a subsystem; thus, software safety is a part of the system’s safety .• 3.0 Safety File.—This report contains the documentation that demonstrates the level of safety built into the system and identifies limitations for the system’s use and operation. In essence, it is a “proof of safety” that the system and its operation meets the appropriate level of safety for the intended application. It starts from the beginning of the design, is maintained during the full lifecycle of the system, and provides administrative support for the safety program of the full system. • 4.0 Safety Assessment.—The independent assessment of the Safety File is addressed. It establishes consistent methods to determine the completeness and suitability of safety evidence and justifications. This assessment could be conducted by an independent third party. • 5.0 Safety Framework Guidance.—It is intended to supplement the safety framework reports with guidance providing users with additional information. The purpose is to assist users in applying the concepts presented. In other words, the safety framework is what needs to be don and the guidance is the how it can be done. The guidance information reinforces the concepts, describes various methodologies that can be used, and gives examples and references. It also gives information on the benefits and drawbacks of various methodologies. The guidance reports are not intended to promote a single methodology or to be an exhaustive treaty of the subject material. They provide information and references so that the user can more intelligently choose and implement the appropriate methodologies given the user’s application and capabilities. [ ]

Jan 9, 2001

By T. H. Jeffers

The U.S. Bureau of Mines has developed porous beads containing immobilized biological materials such as sphagnum peat moss for extracting metal contaminants from waste waters. The beads, designated as BIO-FIX beads, have removed toxic metals from over 100 waters in laboratory tests. These waters include acid mine drainage (AMD) water from mining sites, metallurgical and chemical industry waste water, and contaminated ground water. Following the laboratory studies, cooperative field tests were conducted to evaluate the metal adsorption properties of the beads in column and low-maintenance circuits, determine bead stability in varied climatic situations, and demonstrate the beads' potential as a viable waste water treatment technique. Field results indicated that BIO-FIX beads readily adsorbed cadmium, lead, and other toxic metals from dilute waters; effluents frequently met drinking water standards and other discharge criteria. The beads exhibited excellent handling characteristics in both column and low-maintenance circuits, and continued to extract metal ions after repeated loading-elution cycles. Based on laboratory and field data, cost evaluations for using BIO-FIX technology to treat two AMD waters were prepared. Operating costs for BIO-FIX treatment, which ranged from $1.40 to $2.30 per 1,000 gal of water treated, were comparable with chemical precipitation costs.

Jan 1, 2010

By Thomas J. Fisher, John J. Sammarco, Gary L. Mowrey, Edward F. Fries

This report (Safety File 3.0) is the fourth in a nine-part series of recommendations addressing the functional safety of processor-controlled mining equipment. It is part of a risk-based system safety process encompassing hardware, software, humans, and the operating environment for the equipment’s life cycle. Figure 1 shows a safety framework containing these recommendations. The reports in this series address the various life cycle stages of inception, design, approval and certification, commissioning, operation, maintenance, and decommissioning. These recommendations were developed as a joint project between the National Institute for Occupational Safety and Health and the Mine Safety and Health Administration. They are intended for use by mining companies, original equipment manufacturers, and aftermarket suppliers to these mining companies. Users of these reports are expected to consider the set in total during the design cycle. • 1.0 Safety Introduction.—This is an introductory report for the general mining industry. It provides basic system/software safety concepts, discusses the need for mining to address the functional safety of programmable electronics (PE), and includes the benefits of implementing a system/software safety program. • 2.1 System Safety and 2.2 Software Safety.—These reports draw heavily from International Electrotechnical Commission (IEC) standard IEC 61508 [IEC 1998a,b,c,d,e,f,g] and other standards. The scope is “surface and underground safety-related mining systems employing embedded, networked, and nonnetworked programmable electronics.” System safety seeks to design safety into all phases of the entire system. Software is a subsystem; thus, software safety is a part of the system’s safety. • 3.0 Safety File.—This report contains the documentation that demonstrates the level of safety built into the system and identifies limitations for the system’s use and operation. In essence, it is a “proof of safety” that the system and its operation meet the appropriate level of safety for the intended application. It starts from the beginning of the design, is maintained during the full lifecycle of the system, and provides administrative support for the safety program of the full system. • 4.0 Safety Assessment.—The independent assessment of the safety file is addressed. It establishes consistent methods to determine the completeness and suitability of safety evidence and justifications. This assessment could be conducted by an independent third party. • 5.0 Safety Framework Guidance.—It is intended to supplement the safety framework reports with guidance providing users with additional information. The purpose is to assist users in applying the concepts presented. In other words, the safety framework is what needs to be done and the guidance is the how it can be done. The guidance information reinforces the concepts, describes various methodologies that can be used, and gives examples and references. It also gives information on the benefits and drawbacks of various methodologies. The guidance reports are not intended to promote a single methodology or to be an exhaustive treatment of the subject material. They provide information and references so that the user can more intelligently choose and implement the appropriate methodologies given the user’s application and capabilities. [ ]

Jan 5, 2002

By James P. Ulery, Jon C. Volkwein

The U.S. Bureau of Mines investigated a method of using inert gas to prevent the formation of explosive gas mixtures in auger highwall mining of coal. A combination of gasoline and diesel engine exhaust gases was introduced into the auger drill hole using a short section of pipe located at the collar. Gas samples were taken and analyzed on-site with infrared detectors for oxygen, carbon dioxide, methane, and carbon monoxide. Evacuated bottle samples were also taken and analyzed by gas chromatography in the laboratory. These gas results were analyzed for explosibility. Coal samples from various depths were used to obtain the gas content of the coal using the modified direct method. Personal expo- sure to carbon monoxide was also monitored. The highest methane level observed was 9.55%. The levels of inert gas (carbon dioxide and nitrogen) were sufficiently high to prevent any ignition of the methane. Results showed that for all conditions during mining, gas concentrations were nonexplosive. The gas content of the coal was about 0.30 cm3/g. The maximum personal time-weighted average sample for carbon monoxide was 20 ppm. This system provides a safe, inexpensive, simple method for pre- venting explosions during auger mining.

Jan 1, 1993

By Jon C. Volkwein

The U.S. Bureau of Mines investigated a method of using inert gas to prevent the formation of explosive gas mixtures in auger highwall mining of coal. A combination of gasoline and diesel engine exhaust gases was introduced into the auger drill hole using a short section of pipe located at the collar. Gas samples were taken and analyzed on-site with infrared detectors for oxygen, carbon dioxide, methane, and carbon monoxide. Evacuated bottle samples were also taken and analyzed by gas chromatography in the laboratory. These gas results were analyzed for explosibility. Coal samples from various depths were used to obtain the gas content of the coal using the modified direct method. Personal expo- sure to carbon monoxide was also monitored. The highest methane level observed was 9.55%. The levels of inert gas (carbon dioxide and nitrogen) were sufficiently high to prevent any ignition of the methane. Results showed that for all conditions during mining, gas concentrations were nonexplosive. The gas content of the coal was about 0.30 cm3/g. The maximum personal time-weighted average Sample for carbon monoxide was 20 ppm. This system provides a safe, inexpensive, simple method for preventing explosions during auger mining.

Jan 1, 2010

By P. Cole Gregory, Michael R. Yenchek, John C. Edwards

The U.S. Bureau of Mines investigated the performance of portable power cables under transient conditions. This research had a twofold purpose: (1) to define the thermal characteristics of electrically overloaded trailing cables, and (2) to conceptualize electrical protection for cables that allows maximum cable efficiency without diminishing electrical safety in underground mines. Several tasks were under- taken in support of these goals during the 3-year research effort. Overload tests ranging from 2 to 12 times rated ampacity were conducted in the Bureau's Mine Electrical Laboratory. Two thermal models of energized type G-GC trailing cables were constructed, one based on thermodynamic theory and the other using empirical data from previous Bureau load tests. The empirical model was then incorporated into an interactive computer program that can assist designers and approvers of mining machines in selecting the appropriate size trailing cable. This program can be the basis for a cable protection system that ensures that cables are not the source of fires, ignitions, burns, or explosions underground.

Jan 1, 1993

By Michael R. Yenchek

The U.S. Bureau of Mines investigated the performance of portable power cables under transient conditions. This research had a twofold purpose: (1) to define the thermal characteristics of electrically overloaded trailing cables, and (2) to conceptualize electrical protection for cables that allows maximum cable efficiency without diminishing electrical safety in underground mines. Several tasks were undertaken in support of these goals during the 3-year research effort. Overload tests ranging from 2 to 12 times rated ampacity were conducted in the Bureau's Mine Electrical Laboratory. Two thermal models of energized type G-GC trailing cables were constructed, one based on thermodynamic theory and the other using empirical data from previous Bureau load tests. The empirical model was then incorporated into an interactive computer program that can assist designers and approvers of mining machines in selecting the appropriate size trailing cable. This program can be the basis for a cable protection system that ensures that cables are not the source of fires, ignitions, burns, or explosions underground.

Jan 1, 2010

By John J. Sammarco, Edward F. Fries

This report (Independent Functional Safety Assessment 4.0) is the fifth in a nine-part series of recommendations addressing the functional safety of processor-controlled mining equipment. It is part of a risk-based system safety process encompassing hardware, software, humans, and the operating environment for the equipment’s life cycle. Figure 1 shows a safety framework containing these recommendations. The reports in this series address the various life cycle stages of inception, design, approval and certification, commissioning, operation, maintenance, and decommissioning. These recommendations were developed as a joint project between the National Institute for Occupational Safety and Health and the Mine Safety and Health Administration. They are intended for use by mining companies, original equipment manufacturers, and aftermarket suppliers to these mining companies. Users of these reports are expected to consider the set in total during the design cycle. • 1.0 Safety Introduction.—This is an introductory report for the general mining industry. It provides basic system/software safety concepts, discusses the need for mining to address the functional safety of programmable electronics (PE), and includes the benefits of implementing system/software safety program. • 2.1 System Safety and 2.2 Software Safety.—These reports draw heavily from International Electrotechnical Commission (IEC) standard IEC 61508 [IEC 1998a,b,c,d,e,f,g] and other standards. The scope is “surface and underground safety-related mining systems employing embedded, networked, and nonnetworked programmable electronics.” System safety seeks to design safety into all phases of the entire system. Software is a subsystem; thus, software safety is a part of the system’s safety. • 3.0 Safety File.—This report contains the documentation that demonstrates the level of safety built into the system and identifies limitations for the system’s use and operation. In essence, it is a “proof of safety” that the system and its operation meets the appropriate level of safety for the intended application. It starts from the beginning of the design, is maintained during the full lifecycle of the system, and provides administrative support for the safety program of the full system. • 4.0 Safety Assessment.—The independent assessment of the safety file is addressed. It establishes consistent methods to determine the completeness and suitability of safety evidence and justifications. This assessment could be conducted by an independent third party. • 5.0 Safety Framework Guidance.—It is intended to supplement the safety framework reports with guidance providing users with additional information. The purpose is to assist users in applying the concepts presented. In other words, the safety framework is what needs to be done and the guidance is the how it can be done. The guidance information reinforces the concepts, describes various methodologies that can be used, and gives examples and references. It also gives information on the benefits and drawbacks of various methodologies. The guidance reports are not intended to promote a single methodology or to be an exhaustive treatment of the subject material. They provide information and references so that the user can more intelligently choose and implement the appropriate methodologies given the user’s application and capabilities. [ ]

Jan 5, 2003

By F. H. Nehl

The U.S. Bureau of Mines investigated the selective electrowinning of Ag and Au from cyanide solutions contaminated with Cu with the goal of decreasing the amount of Cu codeposited. Decreasing Cu codeposited will reduce refinery costs. Direct current was applied to the cell in pulsed and square wave voltages at 0.070 A?h per 150 mL of solution. Times tested for each cycle ranged from 1 to 10,000 ms. Graphite, lead, and stainless steel were evaluated as electrode materials. Square wave electrowinning at 70° C gave the best separation of Ag and Au from Cu. Applying 2.5 V during the duty cycle, 0.0 V the rest of the period, a duty cycle of 10 to 30 pct, and a period of 100 to 1,000 ms gave the following results: Ag concentrations decreased from 34 to 0.1µg/mL, Au concentrations decreased from 54 to 0.2 µg/mL, and Cu concentrations remained almost constant at 560 µg/mL.

Jan 1, 2010

By W. K. Collins

Engineered scavenger compounds (ESC's) developed by the U.S. Bureau of Mines are a novel class of compounds that selectively can recover a desired element from a solid or molten alloy. Lithium titanate (L2Ti307 or Li2O?3Ti02) is used as an ESC to recover lithium (Li) from aluminum-lithium (Al-Li) alloys. X-ray diffraction measurements have shown that Li2Ti307 undergoes a phase change during scavenging from an orthorhombic structure to a hexagonal structure. This change is due to the incorporation of lithium in the matrix of the material and the effect of temperature. Although both phases are metastable, the hexagonal phase that forms during the scavenging of lithium from Al-Li alloys appears to be the more stable phase. Recovering lithium from the ESC by electrodeposition does not cause the structure to revert to the orthorhombic phase. The orthorhombic and the hexagonal structures of Li2Ti307 have similar scavenging capacities for lithium. This report proposes a new mechanism for the phase transformation.

Jan 1, 2010

By Gregory M. Molinda

The U.S. underground coal miner faces a continuing hazard from the fall of roof. At the root of many injuries and fatalities are weak or defective roof strata. Throughout mining history, millions of miles of entry have provided exposure of every conceivable geologic roof hazard. This report describes the geologic origin, association, and potential danger from the most common hazards. Discussions of weak rock include drawrock, rider coals, head coal, stackrock, and stream valley effects. Discontinuities, or roof defects, are described including, clay veins, slickensides, joints, and paleochannels. A number of examples from U.S. coalfields are used to document geologic structure and associated hazards. Roof fall analysis is a methodology used by NIOSH for hazard recognition and prevention; its application and benefit to the industry are discussed.

Jan 10, 2003

By A. J. Miscoe, W. M. McKewan

A unique machine for inducing bending fatigue in wire ropes was built at the U.S. Bureau of Mimes' Pittsburgh Research Center. This machine can produce nine levels of degradation through repetitive cycling of long samples of wire ropes of the types used in the mining industry. This report provides an analysis of the results of the first wire rope to be fatigued on this machine. These results have indicated that as a wire rope accumulates bending cycles, its strength first decreases because of wear and then in- creases due to cold working of the wires. As the amount of cold working increases, more and more of the embrittled wires break and the strength of the rope decreases rapidly. In this test, application of several of the regulatory retirement criteria to various sections of the rope suggests that there may be some inconsistency among them.

Jan 1, 1993

By A. J. Miscoe

A unique machine for inducing bending fatigue in wire ropes was built at the U.S. Bureau of Mines' Pittsburgh Research Center. This machine can produce nine levels of degradation through repetitive cycling of long samples of wire ropes of the types used in the mining industry. This report provides an analysis of the results of the first wire rope to be fatigued on this machine. These results have indicated that as a wire rope accumulates bending cycles, its strength first decreases because of wear and then in-creases due to cold working of the wires. As the amount of cold working increases, more and more of the embrittled wires break and the strength of the rope decreases rapidly. In this test, application of several of the regulatory retirement criteria to various sections of the rope suggests that there may be some inconsistency among them.

Jan 1, 2010

By Ronald S. Conti

A new U.S. Bureau of Mines 6.8-L ignitability furnace was used to study the thermal autoignitability of dust clouds. This furnace has a quartz window to allow observation of the early stages of the ignition process and to allow measurement of the dust explosion temperature. Thermal ignitability data were obtained for various carbonaceous and metal dust clouds, with particular emphasis on various ranks of coal dusts. One of the reasons for the construction of the new 6.8-L furnace was to evaluate the effect of chamber volume on the measured autoignition temperatures. Therefore, data from the 6.8-L furnace were compared with data measured earlier in a 1.2-L furnace. The conclusion is that the autoignition temperatures measured in the 6.8-L furnace were only slightly lower on average than those from the 1.2-L furnace. These data on the minimum autoignition temperatures of various materials will be useful in analyzing the thermal ignition hazards of dust clouds in the mining industry and other industries that manufacture, process, or use combustible dusts.

Jan 1, 2010

By William W. Aljoe

The hydrologic characteristics of two abandoned underground coal mine sites, near Latrobe, PA, and Uniontown, PA, were investigated by the U.S. Bureau of Mines for possible implementation of alkaline injection into the mine pools as a means of abating their acid discharges. The Latrobe site was chosen for a one-time application of alkaline injection to achieve a partial, short-term neutralization of a limited portion of the mine pool. A quantity of alkaline reagent (sodium hydroxide) sufficient for a one-time neutralization of the water in this portion of the pool was added. Although nearly all of the neutralizing reagent had moved away from the injection wells within 6 weeks, no evidence of neutralization was noted at the mine discharge during the study period. This lack of neutralization probably occurred because the injection wells did not intercept a primary flow path through the mine. Criteria for successful application of alkaline injection at this or other sites include (1) positive identification of the primary flow paths through the mine pool and (2) addition of quantities of alkaline reagent sufficient to neutralize the entire volume of the pool along the primary flow path.

Jan 1, 2010

By Andrew B. Cecala, Edward D. Thimons, George W. Klinowski

The U.S. Bureau of Mines has designed and evaluated total mill ventilation systems at two different mineral processing operations. Both systems have proven very effective at reducing respirable dust levels throughout the mill in a cost-effective manner. A 25,500-cfm system installed at a clay processing mill provided approximately 10 air changes per hour. This system reduced respirable dust concentrations by approximately 40 pct throughout the mill building. The second evaluation was performed at a silica sand operation. Tests were performed with 50,000 and 100,000 cfm of ventilation to the mill building, corresponding to 17 and 34 air changes per hour. Average mill-wide respirable dust reductions were 36and 64 pct, respectively. Not only did these systems reduce respirable dust concentrations and increase visibility throughout the mills, they were also easy to install and required minimal maintenance. A total mill ventilation system provides a general purging of the mill air; the system should be viewed as a supplemental technique to assist other dust control systems in operation.

Jan 1, 1993

By Andrew B. Cecala

The U.S. Bureau of Mines has designed and evaluated total mill ventilation systems at two different mineral processing operations. Both systems have proven very effective at reducing respirable dust levels throughout the mill in a cost-effective manner. A 25,500-cfm system installed at a clay processing mill provided approximately 10 air changes per hour. This system reduced respirable dust concentrations by approximately 40 pct throughout the mill building. The second evaluation was performed at a silica sand operation. Tests were performed with 50,000 and 100,000 cfm of ventilation to the mill building, corresponding to 17 and 34 air changes per hour. Average mill-wide respirable dust reductions were 36 and 64 pct, respectively. Not only did these systems reduce respirable dust concentrations and increase visibility throughout the mills, they were also easy to install and required minimal maintenance. A total mill ventilation system provides a general purging of the mill air; the system should be viewed as a supplemental technique to assist other dust control systems in operation.

Jan 1, 2010

By Douglas F. Scott

Researchers from the U.S. Bureau of Mines conducted geologic investigations in an area of the Lucky Friday Mine, Mullan, ID, that included the 5300-107 demonstration stope using underhand longwall cut-and-fill mining. Structural analysis of the area suggested that argillite beds form planes of weakness between blocks of brittle quartzite, and energy may be released along these planes and at the junctures of fractures. Mapping argillite beds and fractures in the stope wall rock showed that the planes of these features diverged and that their attitudes corresponded from one wall to the other. Seismic analysis showed that the number and location of events varied as each cut was mined, with about 39 pct of the total number of events occurring above the cut being mined, about 54 pct below, and 7 pct at the same elevation.

Jan 1, 2010

By Alan G. Mayton

A prototype end-cab shuttle car (SC) design has been developed to improve protection and address ergonomic concerns of the SC operator in low coal mines. The new design features an end cab transversely mounted to the SC and equipped with a closed-circuit video system. The end cab was retrofitted to a low-coal SC and evaluated in surface trials at the U.S. Bureau of Mines. During surface trials, test operators evaluated the end-cab SC relative to visibility; cab features-space, seating, controls, and operator position; tramming-inby, outby, and turning corners; and dumping. Trials were conducted using 12 test subjects; 6 were experienced SC operators. Results of the trials were promising. Of the experienced operators, the only operator with low-coal experience gave the new design the highest rating. Four experienced operators rated the end-cab design "better" to "much better" than a standard center-driven, side-cab SC for visibility when tramming, protection from roof and rib hazards, and no change in seat position with direction of travel. This report discusses research to modify a used 21SC JOY SC, retrofit the SC with the Bureau-developed end-cab, and evaluate the retrofitted end-cab SC in surface trials.

Jan 1, 1993

By Alan G. Mayton

A prototype end-cab shuttle car (SC) design has been developed to improve protection and address ergonomic concerns of the SC operator in low coal mines. The new design features an end cab transversely mounted to the SC and equipped with a closed-circuit video system. The end cab was retrofitted to a low-coal SC and evaluated in surface trials at the U.S. Bureau of Mines. During surface trials, test operators evaluated the end-cab SC relative to visibility; cab features-space, seating, controls, and operator position; tramming-inby, outby, and turning corners; and dumping. Trials were conducted using 12 test subjects; 6 were experienced SC operators. Results of the trials were promising. Of the experienced operators, the only operator with low-coal experience gave the new design the highest rating. Four experienced operators rated the end-cab design "better" to "much better" than a standard center-driven, side-cab SC for visibility when tramming, protection from roof and rib hazards, and no change in seat position with direction of travel. This report discusses research to modify a used 21SC JOY SC, retrofit the SC with the Bureau-developed end-cab, and evaluate the retrofitted end-cab SC in surface trials.

Jan 1, 2010