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By Mathias Jern, Ruilin Yang

A blast vibration model has been developed that simulates effects of almost all blast design parameters on the blast vibration peak particle velocity (PPV) from a production blast with multiple blastholes at a given point of interest in the rock. The velocity of detonation (VoD), initiation points, explosive types (density, VoD, energy), charge decoupling, and decking in each blasthole are simulated along with other blast design parameters. The information from signature hole blast vibration and the blast design are the input to the model. The model can be used to assess blast damage in proximity of blastholes as well as far field vibration PPV.

Jan 1, 2019

By Carricajo T., S. Nazari

This paper discusses a unique dynamic solution for optimizing comminution area in real time. The proposed technology is a combination of model predictive controller, optimization methods and real-time digital twin for mineral processing. For grinding area, the ultimate goal of an effective control strategy is to maximize the mineral processing, reduce energy consumption and stabilized size classification. To have a continuous and effective comminution operation, a reliable control system that minimizes the need for human intervention is necessary. The implemented advanced control strategy for comminution area consists of two layers in hierarchical structure. The lower layer objective is to stabilize the process stabilization using model based predictive controller (MPC) technique. The unique MPC used in this layer is called BrainWave™ chosen for its robustness, convergence and delay handling; furthermore, the developed platform offers stable and repeatable solution and has short implementation time. The upper layer is a supervisory control, which sends the preferred process operation points to the lower layer to drive the process towards optimal performance. The goal of this layer is to optimize the process targets, as well as making decision. To increase process performance, automatic ore characteristic adaptations are implemented in this layer. A digital twin of comminution area is built in the second layer that runs amongst the process in parallel. By communicating, the process data in real time, a virtual densitometer is built that is being used in our advance process control strategy. Our control strategy has been developed, tested and implemented in various areas of a copper concentration plant. The targets for implementing advance process control are usually increased throughput, decrease energy consumption and variability reduction in particle size distribution. Overall, the results showed in different mine sites are increase throughput between 2 and 5%, specific energy consumption reduction about 15% and process variability reduction up to 60%. In this paper we discuss the results of the recent implementation of this technology on Minera Los Pelambres, Minera Collahuasi and CAP Minería. Their concentrator plants have installed control systems with the most updates optimization features, for SAG mill, ball mills and thickeners.

Jan 1, 2019

By M. E. Ryan, C. L. Hoebbel, E. J. Haas

DISCLAIMER The findings and conclusions in this paper are those of the authors and do not necessarily represent the official position of the National Institute for Occupational Safety and Health, Centers for Disease Control and Prevention. Mention of any company or product does not imply endorsement does not constitute endorsement by NIOSH. ABSTRACT It has been suggested that effective disaster prevention and response in mining requires that elements of emergency management be incorporated into everyday operations, planning, and decision-making, much in the same way that the industry approaches routine risk management. Since Congress passed the MINER Act in 2006, the newly mandated structural and technological advancements in mine emergency response preparation have been made and are apparent, but measureable improvement in mineworker emergency preparedness is difficult to ascertain. To begin exploring whether measurable indicators of mine workforce preparedness can or should be addressed within a risk management framework, NIOSH researchers examined the datasets from two separate research efforts—one which measured the organizational safety climate and self-reported safety performance, and the other which measured individuals’ perceptions of their own self-escape competency. INTRODUCTION In response to the mine disasters in 2006, the United States Congress passed the Mine Improvement and New Emergency Response Act (MINER Act), which strengthened existing regulations [30 CFR, Part 48] and introduced new provisions to improve mine emergency response. Since that time, new technological and structural features, such as mandated redundant communication systems, personnel tracking systems, and lifelines in primary and secondary escapeways, have been installed in underground coal mines across the country. Additionally, mine operators are required to develop emergency response plans, provide adequate supplies of breathable air throughout the mine, provide more frequent and realistic expectations training, and are required to immediately notify the Mine Safety and Health Administration (MSHA) in the event of an accident. While the structural and technological advancements in emergency preparedness are readily observable and easily measured, levels of individual mineworker preparedness remain difficult to assess. There is a general consensus that deficiencies in competence in the non-routine tasks required for individual miners to effectively respond to a mine emergency likely remain (e.g., National Research Council [NRC], 2013), and NIOSH research continues address this concern (Haas, et al., 2015; Hoebbel et al., 2018). To maximize an operation’s capacity to effectively prevent disasters and/or respond to emergency events, it has been suggested that individual and emergency management efforts be incorporated into everyday operations, planning, and decision-making in much the same way organizations manage routine risks to health and safety (Haddow et al., 2017). To the authors’ knowledge, the mindful intersection of routine risk management policies and practices and emergency prevention and response readiness have yet to be empirically studied within the mining industry.

Jan 1, 2019

By T. Gerritsen, T. Plikas, K. Ochoa, M. Loveless, R. MacRosty, J. Reichart, R. Pula

Sidewall accretion in a smelting furnace plays an important role in furnace integrity as it provides protection to the sidewall cooling elements and thereby extends the furnace campaign life. The extreme thermal and mechanical stresses in the furnace and changes in the slag chemistry can cause the sidewall accretion to melt or break away decreasing the lining protecting the cooling elements. Thin accretion is highly undesirable as it increases the risk of exposing the cooling elements to the molten bath and in the worst case may lead to a failure. Therefore, monitoring the sidewall accretion on an operating furnace is extremely important to manage furnace integrity and to support safe furnace operation. Operators often generate estimates for sidewall accretion and refractory thickness using either copper cooler temperatures or heat load into the cooling water circuits. Multivariate statistical models, on the other hand, have the capability to consider all the process measurements simultaneously to provide a more reliable estimate. This paper describes the application of multivariate statistical models for sidewall integrity monitoring on a Flash Converting Furnace (FCF) and also discusses the online implementation of these models as the Sidewall Accretion Monitoring System. INTRODUCTION Rio Tinto’s Kennecott Utah Copper (KUC) smelter located near Salt Lake city, Utah operates a Flash Smelting Furnace (FSF) and a Flash Converting Furnace (FCF) to produce high-grade matte and blister copper respectively. Since the commissioning of smelter in 1995, several improvements were made to these furnaces to increase their efficiency and operational safety. At present, Kennecott smelter is known to be among the lowest-emission and highest energy recovery copper smelters in the world. Since the smelter start-up, Kennecott has invested in several advanced furnace monitoring practices to evaluate the integrity of the furnaces and improve their campaign life. An example is their temperature monitoring system installed for the smelting and converting furnaces, which continuously monitors the furnace sidewall temperatures and notifies the operators during temperature excursions. During an investigation on the converting furnace, it was revealed that there were frequent temperature excursions in the settler sidewall area towards the reaction shaft end of the furnace that caused significant furnace downtime. The reason for the sidewall temperature excursions was not clearly known.

Jan 1, 2019

By Shonn K. McNeill, Joshua Micah Hoffman

Security engineering is similar to other forms of engineering – the design is guided by the loads, materials, and desired function. For facility design, the load is the threat. Facilities that are designed with considerations for explosive hazards are designed with a shot, or series of shots, of a given size and distance from key locations. These facilities range from office buildings and industrial sites in developed nations to military and police stations in contingency areas. The challenge is the design shots are not often communicated to facility owners and managers. If the hazards change, whether it’s due to an increased capacity to cause damage by a threat or a decrease in capacity by a structure, not knowing the design shot means not knowing if security design needs to change. Blast modeling is an engineering tool that can be used to reverse engineer what a facility is suitable for, as well as be a tool for modifying security design for new conditions. This paper will examine military and civilian examples, including a case study of a military facility that did not know their as-built conditions and had to be rapidly closed; due to the determination their security engineering shortcomings could not be mitigated.

Jan 1, 2019

By P. E. Mather, M. J. M. Krane

Uncertainty quantification is a means of articulating the reliability of model estimations. Models of copper pyrometallurgical processes have been published for decades but discussion of their reliability has typically been terse and qualitative, mitigating understanding of their exact applicability to industrial situations. This presentation shows basic uncertainty propagation and Bayesian model calibration, two powerful uncertainty quantification tools, applied to a reduced order model of copper fire/anode refining. The implications of the uncertainty quantification analyses on the applicability of the model results to industrial practice are then discussed. Finally, other possible applications of uncertainty quantification to copper extractive metallurgy are explored. INTRODUCTION Modern copper production operations, including mining operations through wire drawing factories, are ubiquitously heavily instrumented. Most mine-sites and smelters have large repositories of historical data. That said, much of this data is not exploited to its maximum effect. This proceeding provides examples of using uncertainty quantification (UQ) to maximize the informational yield of the data collected from a fire-refining operation. Anode/Fire Refining is the final pyrometallurgical step in the production of copper anodes; it is an essential and universally employed processing step at smelters (Schlesinger, King, Sole, & Davenport, 2011). Much like the smelting and converting furnaces further up the process stream, anode furnaces are difficult to instrument due to their high temperature and the corrosive and/or caking quality of their offgas. This makes continuous and accurate measurement of the streams leaving the unit operation, e.g. liquid copper, slag, and offgas very difficult. As an example, offgas flowmeters, while providing continuous draft values, could miss the actual draft value by tens of percent due to caking or corrosion. UQ methods account for the uncertainty in process measurements and parameter values; they use a process model with measurements of performance indices to provide better and better estimations of process performance. This proceeding will first introduce a surrogate model for copper fire refining, made from a 1D, transient, reacting flow model of the process presented elsewhere in these proceedings (Mather & Krane, 2019). Discussion of the data used to make the surrogate model, as well as the creation of the surrogate model, will be included. Then, a Monte Carlo simulation will be performed, showing the expected soot production rate based on the surrogate model and assumptions about the uncertainty in the model’s parameters. Finally, the surrogate model parameters will be calibrated in a Bayesian way; this will tell what the actual uncertainty in the parameters are, given a set of observed industrial data and prior assumptions of the observations’ and parameters’ uncertainty.

Jan 1, 2019

By Bo-Hyun Kim, Mark K. Larson

"Bumps remain a critical safety concern in underground coal mining, despite significant advancements in engineering controls. These events occur when relatively high stresses in a coal pillar in conjunction with low confinement exceed the pillar’s critical capacity, causing the pillar to rupture without warning. Floor failure often occurs and can be an indicator of bump risk, as it is strongly associated with brittle failure known as spalling under a lower confinement. Significant floor heave at a western U.S. coal mine has been observed where the pillar width in a three-entry gate road system was 53 m, while no significant floor heave was observed where the pillar width in another gate road system was 22 m. This phenomenon was widely reported in the region and at another mine in another western coal field it has been reported that larger pillars are always associated with floor heave. In this study, a spalling model based on the S-Shaped brittle failure criterion and associated with the anisotropic characteristics of the materials was used in FLAC3D. The observed floor heave phenomenon associated with the larger pillars was demonstrated using this modeling approach.INTRODUCTIONFloor failure in a coal mines often inhibits longwall mining operation, as large displacement of floor strata, known as floor heave, interferes with travel, access, ventilation, and equipment operation. Aggson (USBM 1978) investigated floor heave in West Virginia where underclay is relatively strong and high horizontal stress is present. It was reported that the failure mode is mainly by buckling rather than by plastic flow.This study was developed as part of an effort by the National Institute for Occupational Safety and Health (NIOSH) to better understand rock mass behavior in longwall coal mines in highly stressed, bump-prone ground. More specifically, this study attempts to explain through numerical models small energy releases in the form of floor heave. The authors believe that brittle rock failure is associated with both floor heave and some bump mechanisms, if not directly involved in their cause."

Jan 1, 2019

By Yves Prévost, Guy St-Amant, Guillaume Dion

In 2010, the foreseen increase of copper grade in feed concentrate at the Horne Smelter was a significant challenge to maintain a steady copper flow throughout the process. The Horne Smelter process includes a Noranda Reactor, a Noranda Converter, pyro refining vessels and anode furnaces. Of the many challenges involved, improving the single casting wheel performance was one of the key topics. Its reliability had to be improved to meet the new production objectives, as anode copper production was to increase from 170 000 to 225 000 tonnes/year. A multidisciplinary team was dedicated to improve the casting wheel availability. The improvement project allowed pinpointing failure modes and reviewing operational and maintenance practices. The common understanding developed by the team allowed improving small components with a high gain-to-effort ratio. The project allowed reaching operational targets without any significant investment. INTRODUCTION In operation since 1927, the Horne Smelter, located in Rouyn-Noranda, in Quebec, has undergone several technological changes since its original construction. Built to smelt the Horne mine concentrates, the smelter also accepted some local custom feeds from the first years of operation. When the Horne mines stopped production in 1976, the plant became a 100% custom smelter. With the development of the Noranda Reactor (1973) and Noranda Converter (1997), the Horne smelter increased its productivity and improved its environmental performance. Continuous improvement of the Horne process allowed maintaining a high level of flexibility in the operation of the smelter, while improving its overall capacity.

Jan 1, 2019

By M. E. Rossi, J. A. Bassan, J. B. Novillo

Sampling and geological models are the basis of recoverable resources models. They are pillars of mineral resources and reserves estimation, and what geostatistical methods for grade estimation should rely upon. The resource model is best estimated if geostatistical methods make good use of sound geologic models. Data collection from the original drill holes, including field procedures and the quality assurance and quality control (QA/QC) of those samples are pillar one of a resource model. The second pillar of the model is the good use of the logged geological information, resulting robust geological interpretations, and the corresponding three-dimensional models of those interpretations. These models are partly subjective and mostly conditioned by the quality of logging and the geologist’s experience. They are also conditioned by the quality of the three-dimensional models built, regardless of the modeling method employed, traditional or implicit. Grade estimation is more commonly done by applying some geostatistical method and using the two basic sources of information, data and geologic model. Multiple stages are involved in this process, and in all of them there are uncertainties and risks that have to be dealt with. Knowledge, understanding, interpretation, and management of the model’s fundamentals are critical, given that they directly affect its accuracy and predictive quality. The mitigation of related risks allows for the creation of opportunities, generating value and reducing the project’s uncertainty. This paper discusses some of the key variables, uncertainties, and risks involved in the resource modeling process, illustrating with specific examples; discusses possible risk mitigation alternatives, and proposes best practices to avoid or mitigate those uncertainties. Emphasis is placed on taking advantage of technological advances without ignoring fundamentals. INTRODUCTION In the area of mineral resource estimation, one alarming trend that these authors have observed in the past 20 years or so is that the care and diligence in checking the work as it progresses has generally diminished. This is, perhaps, an unintended consequence of the availability of new technologies and tools that attempt simplify and speed up the work involved. This has led to a more casual attitude towards checks and balances that have to be in place at any given stage of the process before proceeding to subsequent stages, as best practices dictate. To some extent, some of these aspects are covered in international standards for resource estimates reporting (JORC, 2012; CIM, 2010). But these are broad, and do not specifically recommend best practices to a level of detail that would have an impact on certain aspects of the process. There are numerous references in the geology and mining journals and conferences that discuss the consequences of poor recoverable resource models (Baker and Giacomo, 1998; Vaughan, 1997).

Jan 1, 2019

By W. Kempson

"As has been noted on numerous occasions, the vertical shafts being sunk around the world are all tending to get deeper as we seek to take advantage of higher grades of minerals which can sometimes be found at greater depths. One of the challenges with these deeper shafts is the requirement to supply services to the mine’s operations at depth as well as the requirement to dewater the mine. Both the supply of water and the dewatering of mines is generally done using piping. With the greater shaft depths, this piping is now required to contain higher pressures as well as to accommodate changes in temperature resulting from normal mine operations. This paper will discuss the requirements for the design of high pressure piping in deep vertical shafts. The discussion will start with the general definition of the systems and the detailed design requirement. Once this is clearly outlined, we will discuss the options available for fulfilling these requirement as well as the advantages and disadvantages of each of the systems. We will finish with the installation recommendations and provide a basis for the maintenance of these systems. INTRODUCTION Piping in vertical shafts is used to provide a number of services in underground workings. These services vary depending on geographical location and the type of the ore body which is being mined. For example, in the Zambian Copper mines, one of the largest requirements for in shaft piping is for dewatering. Similarly in the Gold deposits in the West Wits basin as well as the deep level Copper deposits in Arizona, one of the largest uses for the piping is the supply of a cooling medium to underground workings to create a safe working environment (this can in the form of water or of glycol depending on the application). In South Africa, systems were installed which used the hydrostatic head which is generated from supplying chilled water to mines whose depths exceeded 2,000 m below surface. This chilled water was supplied as a closed system, allowing for high pressures to be generated which was then used to supply useful work (for example, Rock Drills, Face Cleaning and other ancillary services) whose power was traditionally supplied by compressed air or electricity. This system was initially researched by Chamber of Mine in South Africa. The design pressure range of these systems is 14 MPa to 18 MPa."

Jan 1, 2019

By E. Goris Cervantes

"A theoretical framework based on a detailed analysis of mine operations data from an oil sands mine in northern Alberta and the static simulation of truck cycle times are developed, verified, and validated in this paper. Implementation of this framework provides better results than existing tools that rely solely on manufacturer data. This, therefore, aids in efficient equipment planning for the life of the mine. The use of this framework to modify existing productivity curve estimation methods currently in use at the mine site is also proposed. This method replaces “loaded flat haul” with “loaded effective flat haul” in the productivity estimation. Validation of the model results in a 4% overestimation of productivity, versus an underestimation of more than 10% when using the existing in-house method. ¦ KEYWORDS Equipment planning, Life-of-mine (LOM) planning, Oil sands, Productivity, Truck cycle times RÉSUMÉ Un cadre théorique fondé sur une analyse détaillée des données relatives aux activités minières d’une exploitation de sables bitumineux dans le nord de l’Alberta et la simulation statique des temps de cycle des camions sont développés, vérifiés et validés dans cet article. La mise en oeuvre de ce cadre offre de meilleurs résultats que ce que proposent les outils existants, lesquels se basent uniquement sur des données des constructeurs. Ceci contribue donc à une planification efficace de l’équipement pour des projets relatifs à la durée de vie de la mine. On propose également de se servir de ce cadre pour modifier les méthodes d’estimation de la courbe de productivité actuellement utilisées sur le site minier. Cette méthode remplace le concept de loaded flat haul (la distance parcourue par des camions avec un chargement du point de collecte jusqu’au point de déchargement des résidus miniers) par celui d’effective loaded flat haul (la distance relative parcourue par des camions avec un chargement du point de collecte jusqu’au point de déchargement des résidus miniers) dans l’estimation de la production. La validation du modèle résulte en une surestimation de 4 % de la productivité, par rapport à une sous-estimation de plus de 10 % avec la méthode actuellement utilisée en interne. ¦ MOTS CLÉS planification de la durée de vie de la mine, planification de l’équipement, productivité, sables bitumineux, temps de cycle d’un camionINTRODUCTION One aspect that differentiates oil sands mines in northern Alberta from conventional hard-rock mining is the environment in which they operate. Due to ground characteristics, producers in the region experience roads with very high rolling resistance (RR) that, in turn, negatively affect haul-truck performance and greatly increase fuel consumption and emissions. Oil sands mining companies use some of the largest haul trucks in the world. In addition, oil sands mines cover more extensive areas than hard-rock pits, resulting in longer haul distances on roads made of comparatively more viscous material."

Jan 1, 2019

"The Hardy Cross algorithm offers a reliable method of solving network systems of fluid flow and has become widely used for solving water and ventilation flow networks. A limitation is that computational iterations and time to solve a network rises rapidly with the size of the model and modern detailed ventilation networks have typically grown to thousands of airways. Non-linear matrix solving methods can offer improved performance, however these are more complex and may be unstable if initial estimates are poor. This paper presents improvements that can be applied to the traditional Hardy Cross algorithm to greatly reduce iterations and solving time for large ventilation models. INTRODUCTION The Hardy Cross algorithm (Cross, 1936), was originally developed to solve water flow in city and urban pipe networks. Using principles of Kirchhoff’s electricity current laws, Hardy Cross developed an iterative algorithm for solving non-linear equations associated with network water flow. Traditional network analysis research refers to the various members of system networks as branches, nodes and meshes. This terminology has been changed in this paper to airways, junctions and loops respectively which are terms more familiar to engineers in mine ventilation. When Kirchhoff’s laws are applied to fluid networks, the following assumptions can be made: •The sum of fluid flows into a junction must equal the sum of fluid flows out of the junction.•The sum of pressure losses around any loop through a network system must be equal to zero.An iterative solution can therefore be achieved by initially guessing flow in a network, calculatingthe pressure losses around the network loops (Figure 1), and applying flow corrections using Newton’s method for each loop if the sum of the pressure losses does not equal zero. To solve the system, a loop must be defined for every segment or series of segments between a junction of 3 or more airways.The Hardy Cross algorithm has been used extensively for ventilation network analysis since the introduction of the first electronic computers (Tien, 1997), however numerous other variations and methods have since been developed through the use of matrices to solve the required system of nonlinear equations. Commonly used algorithms such as the Newton Raphson method (Brown, 1969), the Gradient method (Todini & Pilati, 1988), the Linear Theory method (Gupta & Prasad, 2000), and Coupled Network Solver (G. Danko, 2008) have found general use in fluid flow network solvers (Rossman, 2000). Despite poor and sometimes unpredictable convergence performance however, the Hardy Cross algorithm still has unique properties that make it attractive for ventilation models. Some benefits are:"

Jan 1, 2019

By S. Hopkins, J. Nolan, S. Gillis

"Cast in place concrete shaft linings have been used in many salt and potash shafts sunk in North America over the last 100 years. A large number of these shafts have exceeded their initial design lives and as producers look to extend the life of their operational assets, maintenance costs and shaft downtime will, in many cases, continue to rise unless repair work is undertaken. Successfully implementing concrete liner repair schemes in operating salt and potash shafts is complicated due to their age, environment and time constraints during inspection, detailed design and construction. This paper outlines a general approach to the repair of concrete-lined portions of these shafts, based on lessons learned from the authors’ involvement in a recent repair project. INTRODUCTION Prior to the recent boom in potash mine construction many of North America’s potash mine shafts were entering their sixth continuous decade of production (Table 1). Of North America’s salt mines, one has been in continuous production, for nearly nine decades.As would be expected, considering the environment in which these liners operate and the age of the material, the concrete-lined sections of the shafts outlined in Table 1 have been noted by the authors to have lost both cross-sectional thickness and strength over time. Since construction, three principal factors have contributed to this loss in section/strength; (1) physical degradation (impact, freeze/thaw or rebar expansion), (2) chemical degradation from brine/water inflows (Neville 1969; Bothwell, 1972) and (3) overstressing of the liner. These factors may act in combination, in which case they can produce more significant distress than individually. Physical degradation There are three main causes of physical degradation of concrete shaft liners. The first is impact from falling debris/tools or equipment (whether large or small), which may damage specific sections of concrete lining as they fall through the shaft. Impacts tend to damage infrastructure fixed to the shaft liner more than the liner itself, so damage from this mode of failure is usually localised, for example, where bolts fixing a shaft services bracket to the wall have been pulled away, pulling out the concrete around the bolts with them."

Jan 1, 2019

By C. Cristonffanini, S. Nazari

"In the past, simulation was considered to be an offline tool disconnected from plant operation. Advancements in the computation power combined with utilizing physics and chemistry sciences have allowed us to significantly improve the modeling and simulation technology for mining and mineral processing. This paper investigates the benefits of first principle models and simulation by connecting them to real time operation. Process data are connected to high fidelity models executed in parallel to the operation. In recent literature, this concept is known as Digital Twins. The Digital Twin is used for various purposes such as optimization, virtual instrumentation and condition monitoring. Using IDEAS™ simulation software we are able to construct a digital twin for different equipment inside a mineral processing plant. Two case studies for building a digital twin for the primary hydrocyclone feed pump and thickener underflow are presented. Using the pump’s model, a digital twin is developed and is installed in a gold extraction plant that is able to infer the slurry density in real time. Additionally, it is used for detecting sanding in the pipes and impeller condition monitoring.INTRODUCTION Since the eighties, thanks to advances in computation technologies, computer based simulation of processes using first principle models has become a well-known engineering tool for various industries. As our understanding of processes has increased, their representative models have become more realistic and more sophisticated. Due to this increase of accuracy, use of simulation is becoming more fundamental in process industries. The main goals to use accurate simulation is to decrease the engineering and construction cost, optimize the process design and improve the operation performance by decreasing operation cost and increasing efficiency. The term Digital Twin was first introduced in 2010 by NASA (Shafto et al., 2012) in aerospace industry. Subsequently, the concept quickly spread through other industries. As of today, no standard organization has provided an official and unique definition of Digital Twin for process industries. However, there are three important aspects that are common throughout various descriptions. When simulation is core functionality of the process (1) along the entire life cycle of the plant (2) with direct linkage to operation (3), it is called that process has a Digital Twin. According to Gartner, the concept of Digital Twin has elected as fourth most important disruptive technology for the year 2018 (https://www.gartner.com/, 2017)."

Jan 1, 2019

By M. Li, T. H. Dubaniewicz, H. N. Dougherty

"INTRODUCTION Underground mines have the risk of accumulation of gases if not ventilated properly or during and after emergency situations when ventilation controls become damaged or stop working. Common gases that are monitored in underground coal are carbon monoxide (CO), oxygen (O2), and methane (CH4). Methane is a gas found in coal and released through mining; its explosive range is between 5% and 15%. Methane is commonly monitored on all mining equipment and with handheld gas sensors carried by most underground coal miners. Fiber optics (FO) is a popular technology applied in underground mining, particularly for its electric isolation. Many miners are familiar with FO cables hung throughout the mine, which are primarily used in the communication of voice and data (Taylor et al. 2010). Advancements in laser and fiber optics have made this technology well suited for gas sensing the harsh environment of mining applications. The work of the U.S. Bureau of Mines on the use of fiber optic monitoring of gases in mines started in 1992. Dubaniewicz et al. (1992, 1993, 1995, 1999, 2003) developed prototype gas sensors, including methane gas sensors, for research purposes. Previous research (Dubaniewicz & Chilton 1992) identified potential fiber optic gas detection cross-sensitivities associated with the index of refraction of various gases. Index of refraction effects was noted for carbon dioxide (CO2), which is produced in significant quantities by mine fires or explosions. NIOSH released a broad agency announcement (BAA) for the development and demonstration of mine safety and health technology (CDC NIOSH 2017). The objective of this announcement was to validate a sensor, specifically fiber optic, for the mine environment and test it in an actual working mine. The RSL FO sensor “OptoSniff” provided from this work is capable of hundreds of sensing points over distances of up to 20 km, has a measurement range of 0.05% to 100%, senses in an oxygen- deficient environment, and has no gas cross-sensitivity (RSL, 2014). The RSL system is totally electrically passive outside the central control unit (CCU), which can be housed in an MSHA-approved explosion-proof (XP) enclosure or in a control room outside of the permissive area. The sensor was tested in dusty and signal loss situations, showing it is tolerant of dust, has functioned at signal losses up to 90%, and was successfully tested in a mine environment for a five-month period (Walsh et al. 2014). This paper describes how the RSL FO sensor is used for testing using smoke and its contaminants for applicability in emergency situations. The testing investigates individual contaminants such as CO2, temperature, and smoke. Each test was performed separately and methane concentration, laser power, and response time data were collected."

Jan 1, 2019

By J. Navoyski, B. Macdonald, W. J. Helfrich, J. L. Bellanca, B. Demich

DISCLAIMER The findings and conclusions in this paper are those of the authors and do not necessarily represent the official position of the National Institute for Occupational Safety and Health, Centers for Disease Control and Prevention. Mention of company names or products does not constitute endorsement by NIOSH. ABSTRACT Recent advances in computing, rendering, and display technologies have generated increased accessibility for virtual reality (VR). VR allows the creation of dynamic, high-fidelity environments to simulate dangerous situations, test conditions, and visualize concepts. Consequently, numerous products have been developed, but many of these are limited in scope. Therefore, National Institute for Occupational Safety and Health researchers developed a VR framework, called VR Mine, to rapidly create an underground mine for human data collection, simulation, visualization, and training. This paper describes the features of VR Mine using self-escape and proximity detection as case studies. Features include mine generation, simulated networks, proximity detection systems, and the integration and visualization of real-time ventilation models. INTRODUCTION There are many definitions of virtual reality (VR) that include various levels of immersion and features [1]. Some definitions refer to specific technologies [2], while others are limited to visualization [3]. For this paper, a more general definition of VR will be adopted. VR is defined as the collection of hardware and software that interactively engages users and stimulates their senses within a synthetic or virtual environment. From a hardware standpoint, this can include anything from a phone to a head-mounted display (HMD) to a large-scale theater as well as speakers, microphones, haptic sensors, and interaction devices. The software used to create virtual environments (VEs) generally includes a game engine, custom software components and libraries, and two-dimensional and three-dimensional graphical assets. Recent hardware and software advances have increased the fidelity and availability of VR. New and improved technologies including HMDs and high-resolution monitors and projectors can display sharper, more detailed visualizations. For example, in the past five years between the release of the Oculus Rift DK1 (2013) and the HTC Vive Pro (2018), there was a three-fold increase in resolution along with a 50% increase in the refresh rate. Furthermore, despite early claims that low-cost VR technology was readily available [4], computational power has not been sufficient to handle the large amount of data generated by these systems [5]. In the past five years, however, rendering speeds have more than doubled and memory has more than tripled [6], allowing these visualizations to be incorporated into higher-complexity and -fidelity VEs that more closely mirror the real world. Similarly, software capabilities have also significantly improved through game engine advancements and feature development. In the past several years, game engines have added and improved features such as physics, lighting, platform support (e.g. Android), and asset development integration. Some of the current leading commercial game engines are Amazon Lumberyard, CryEngine, Unreal, and Unity, but this can quickly change as is evident in the literature [7, 8].

Jan 1, 2019

By Greg Canivan, Bernie Hertlein, Les Chernauskas, Joram Amir, Garland Likins, E. Anna Sellountou, Tim Kovacs, Peter Kandaris

Nondestructive testing of drilled shaft foundations via Crosshole Sonic Logging (CSL) is often performed as part of the quality assurance process to assess the soundness of concrete. The intent of CSL testing is to identify irregularities such as soil intrusion, necking, soft bottom, segregation, voids and other defects that could result in poor structural performance of the foundation. Over time, CSL rating criteria based on first arrival time and relative energy have incorrectly evolved to often be the sole means of determining the acceptability of a shaft. Some of these criteria have found their way into regulatory agency specifications, with acceptance values often differing from agency to agency.The purpose of this document is to review the state of the practice (including experience gained over the past 20 years), propose improved CSL rating criteria and make recommendations for additional assessment, as well as educate the industry on the proper interpretation of CSL test. CSL test results alone should not be the sole means of rejecting or accepting a shaft. A task force of industry exerts was formed to review the existing CSL rating criteria and propose improvements where appropriate. The recommendations presented herein are the consensus of the task force, which believes that they should be incorporated into future criteria, codes and specifications. This paper was produced as a joint effort between the Codes and Standards Committee, the Drilled Shafts Committee and Testing and Evaluation Committee. A task force was authorized under Testing and Evaluation Committee. The task force contributed their expertise in web-based discussions often every two weeks over a period of three years. Interested participants were invited to participate at any time. The document had two rounds of broad industry review, two rounds of DFI Technical Advisory Committee reviews, and a Public Comments process. All comments were considered in producing the final document.

Jan 1, 2019

By Kalyani Devabhaktuni, Mike Minton, Mark T. Howe, Yan Zhang

During the procurement phase of a Design-Build (DB) project, design-build contractors must often commit to a fixed price based on limited or incomplete geotechnical information. This lack of information can result in an inaccurate assessment and allocation of project risk to either the contracting authority or the DB contractor. This paper presents a case study of an elevated water tank supported by mixed ground improvement techniques, including Vibro-Compaction (VC), Aggregate Piers (AP) and Compaction Grouting (CG) in East St. Louis, Illinois. An adaptive design and contracting approach provided the best value solution for a complicated set of geotechnical problems, including static bearing capacity and settlement concerns as well as liquefaction induced settlement. Close cooperation between the owner, the tank contractor, the geotechnical engineer and the ground improvement contractor was essential to produce an effective solution. Ground Improvement techniques resolved the geotechnical challenges at the site through adaptive design methods, utilizing progressive rounds of verification and real time data acquisition to achieve performance objectives. This paper details the evaluation of geotechnical criteria, the selection of ground improvement techniques, the adaptive design and implementation of ground improvements, as well as contracting methodologies used to ensure that the best value was provided. PROJECT INFORMATION In November, 2016, CB&I Storage Tank Solutions (McDermott) submitted a design/build proposal for an elevated water tank for Illinois American Water Company (IAW) in East St. Louis, Illinois. The purpose of this tank was to have backup water capacity for power generation. In the RFP, IAW requested two alternate styles of tank: Option 1, a 1250 Million Gallon (MG) Composite Elevated Tank or Option 2, a 1250 MG Waterspheroid tank. Option 1 consisted of a steel tank supported on a concrete tower. Option 2 consisted of a steel tank supported on a steel shaft. The height (determined by IAW) was 140 feet to the top capacity line measured from top of floor slab.

Jan 1, 2019

By Brandon Smith, William Bohlen

Riverbank erosion along the Brazos River has modified the structural support conditions for an existing bridge structure in Southeast Texas. The 8-span, 1,200-foot long bridge was completed in 1992 along Highway 99, a key corridor for the Houston area. Foundation support conditions have been altered due to natural, ongoing river morphology for three bents on the affected riverbank. Recent events include three storms within a three-year period that each exceeded the 500-year return probability. This resulted in accelerated erosion along the northern riverbank. Over forty vertical feet of soil has been removed in some locations. Drilled shaft foundations are now functioning as columns. This review considers the behavior of columns and deep foundation elements due to the modified support conditions. The review ultimately presents a rational methodology for the review of the present and anticipated future bridge configuration with respect to current strength, service, and extreme event limits, with corresponding safety factors for the design. Introduction and Background The Fort Bend Grand Parkway Toll Road Authority (Owner) oversees the State Highway 99 Judge Jodie Stavinoha Bridge over the Brazos River. The 8-span, 1,200-foot long bridge was originally designed with four southern approach spans of 115 feet; a three-span continuous river crossing with span lengths of 195 feet-235 feet-195 feet; and a single northern approach span of 115 feet. Figure 1 provides an overview of the northern portion of the bridge. Table 1 provides a summary of the original bridge substructure configuration. When the bridge was completed, the centerline of the Brazos River was located at midpsan of the main span and the northern high bank was originally located at Bent 7. Erosion process has forced the northern high bank to Abutment 9 (also called Bent 9), and the river centerline during normal flow conditions is located south of Bent 8. The overall estimated river excursion at present day is approximately 270 feet to the north from its original location. An erosion wall that was installed in 2017 limits further erosion of the north river bank within the 300-foot width of the roadway corridor right-of-way. This study was developed to better understand the existing conditions, and to forecast the need, nature, and criteria for potential future improvements.

Jan 1, 2019

By John R. Grillo, Gordian Ulrich, Franz-Werner Gerressen

Most geotechnical construction professionals are aware of piling using hydraulic drill rigs and the so-called Kelly drill mode. Kelly drilling has many advantages as it can work with a wide range of tools facing almost all types of soil and rock conditions. Kelly drilling can also deal with diameters up to 10 ft (3.00 m) and bigger or depths of more than 330 ft (100 m). Nonetheless, there is a concern about Kelly drilling as it is a relatively slow installation process. Therefore, an alternative piling method like Cased CFA (CCFA) Piles (Cased Auger Cast Piles) provides a significant advantage in terms of installation performance, schedule and cost saving potentials. Major application for the Cased CFA system is the secant pile wall construction. Against the traditional secant pile wall systems like fully cased bored piles or CFA secant piling the Cased CFA secant pile wall system has the advantage in cost and time against the fully cased system and in quality against the standard CFA system. This paper will describe the methodology and installation process in general as well as first reference projects carried out in the United States. This paper will present the results in cost and schedule saving using this method. In addition, we will also describe the limitations of this method. INTRODUCTION In the changing construction environment, companies are searching for new technologies or improvement of existing technologies to complete their projects in shorter time frames to provide a good economic solution. Especially with the focus of increasing urbanization, the aim of fast construction becomes more and more important. When thinking of piling, most people will have the same picture in mind: that of a hydraulic drill rig working in Kelly drilling mode; however, the perpetual drill rig development provides a number of options for the execution of specialist foundation projects, either for foundations or for pile walls when using single pass applications like CFA, Cased CFA and Full Displacement Piling (FDP). Single pass means, in general, that the tool is pushed and rotated into the ground to the final depth in one stroke. After reaching the final depth, concreting is started and concrete is pumped continuously while the tool is withdrawn.

Jan 1, 2019