Application of Electronics in Mining Engineering

BY DR. K. N. SINHA

Director, Central Mining Research Station, Dhanbad AND

DR. B. SINGH

Scientist, Central Mining Research Station, Dhanbad

ABSTRACT When compared with other industries, mining industry is lagging behind in making use of the developments in electronics for increasing productivity and safety in Indian mines. This paper deals with the different fields in which electronics can be used in the Indian Mining Industry. In Indian Mines of future, electronics can find application in the use of televisions for controlling underground and surface transport, for transmitting data about the performance of underground machineries and environmental conditions in mines to the manager's desk on the surface, in actually breaking and carrying the mineral without the help of a man and for guiding machines underground. To help the industry in evolving new methods of mining, Central Mining Research Station is carrying out investigation in several mines. For these investigations remote indicating load cells and convergence indicators are required. For investigating the problems of rock bursts and safety in mines transistorised strain indicator is required.

1.0.

Introduction

More and more of electronics is being introduced in different branches of industry. In this respect, mining industry has been lagging behind. In U.S.A., Russia and European countries electronics has found some application to increase productivity and safety in mines. In India also, mining industry cannot lag behind and it is necessary for Indian Scientists to develop suitable electronic devices to increase productivity and safety in Indian mines. This seminar is the proper forum to discuss the different aspects where Indian Electronic Scientists can help the mining industry.

better to deal briefly with the safety requirements of electronic equipments before they are allowed to be used in gassy mines or mines containing explosive atmosphere. Those apparatus, which under normal circumstances do not produce sparks of exceed temperatures capable of igniting gases do not pose any problem in mines. The different types of protection for an apparatus, which under normal circumstances produce sparks or exceed temperature capable of igniting gases, may be as follows : Flame-proof enclosure. Sand-filled apparatus. Pressurised apparatus. Oil-immersed apparatus. Hermetically closed apparatus or gas-tight enclosure. (/) Intrinsically safe circuits, (a) (b) (c) (d) (e)

2.0. Safety Aspect

Before dealing with the possibilities of different uses to which electronics can be put for the benefit of the mining industry, it will be

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APPLICATION OF ELECTRONICS IN MINING ENGINEERING

A flame-proof enclosure (including explosion proof) for electrical apparatus is one which will withstand, without injury, any explosion of prescribed inflammable gas that may occur in practice within it, under practical conditions of operation within the rating of the apparatus enclosed by it and will prevent the transmission of flame such as will ignite the prescribed inflammable gas which may be present in the surrounding atmosphere. The term 'sand enclosure' signifies an enclosure for electrical apparatus in which either all active parts must be covered with layers of granular material in order to prevent the propagation of a flame when an ignition occurs within the layers or in which layers of granular material are used in order to prevent the passing of a flame from one. compartment into another. The term 'pressurized enclosure' signifies an enclosure for electrical machines and apparatus in which the entry of flammable gases or vapours is prevented by maintaining the air or other nonflammable gas within the enclosure at a pressure above that of the external atmosphere. The term 'Oil-immersed apparatus' applies to oil-immersed parts of electrical apparatus, intended to be safe in the sense that flammable gases or vapours over the oil and outside the enclosure will not be ignited. The term 'hermetically closed apparatus' applies to an electrical apparatus which is enclosed within a gas-tight enclosure preventing the entry of flammable gases or vapours. According to the Indian Mines Regulation "Intrinsically safe" as applied to apparatus or associated circuit denotes that any sparking that may occur in normal working is incapable of causing explosion of inflammable gas or vapours. Normally the weight of a flame-proof enclosure may be several times that of the actual apparatus. It is better to make the electronic instruments intrinsically safe rather than relying on flameproof enclosures,

Concerning precautions where gas exists the Indian Electricity Rules specifies the following : "Precautions where gas exists. (i) In any part of a mine or oil-field in which inflammable gas or vapour is normally present or is likely to occur, and in any working adjacent to or approaching any such area, the following additional provisions shall apply in regard to all circuits and apparatus : (a) all signalling or telecommunication circuits shall be constructed, installed, protected, operated and maintained in such a manner as to be intrinsically safe; (b) all cables and apparatus, including portable and transportable apparatus, used at or within 300 yards of any working face (and at any other place in the mine if the percentage of the inflammable gas or vapour in the general body of the air therein exceeds 0'5%) shall be so constructed, installed, protected, operated and maintained as to prevent the risk of open-sparking; and (c) the supply shall be disconnected: (i) immediately, if open sparking occurs, and (ii) during the period required for examination or adjustment of the apparatus which would necessitate the exposing of any part liable to open sparking. The supply shall not be reconnected until the apparatus has been examined by the electrician or.oae of his duly appointed assistants and until the defect, if any, has been remedied or the necessary adjustment made; (d) all electric lamps shall be enclosed in airtight fittings and all lampglobes shall be hermetically sealed;

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APPLICATION OF ELECTRONICS IN MINING ENGINEERING (e) a flame safety lamp shall be provided and maintained in a state of continuous illumination near all apparatus (including portable or transportable apparatus), which remains energised and where the appearance of the flame of such safety lamp indicates the presence of inflammable gas, the supply to all apparatus in the vicinity shall be immediately disconnected and the incident reported forthwith to an official of the mine; provided that where appliances for automatic detection of the percentage of inflammable gas or vapour are employed in addition to the flame safety lamps, such appliances shall be approved by the Inspector of Mines and maintained in perfect working order. (ii) If, any part of the mine, the percentage of inflammable gas in the general body of the air is at any time found to exceed one and one quarter percent, the supply of energy shall be immediately disconnected from all cables and apparatus in the area and the supply shall not be reconnected so long as the percentage of inflammable gas exceeds that amount." In the Central Mining Research Station, Dhanbad, tests are carried out to find out if an electrical apparatus is flame-proof or is intrinsically safe. 3 . 0. Instrumentation 3.3. 3.1. Application of Electronics to Surface Installations and Operations (a) Automatic winding. ( b ) Television to control surface traffic of mine cars. (c) Automatic separation of coal from dirt. (d) Controlling of traffic in coal preparation plant. 3.2. Application of Electronics to Underground Installations and Operations (a) (b) Electronic line signalling for communication. Controlling the loading of mine cars in cages where automatic winding is being practised. Control of locomotives underground without drivers. Manless facesAutomatic breaking and loading of coal without any human help. Automatic advance of supports, control of cutting horizons, etc. Automatic recording of quantity of air, methane concentration, heating of machines, conveyors, etc. Development of wireless telephones underground for rescue and recovery work.

(c) (d)

(e)

(/)

Application of Electronics to Investigate Different Mining Problems (a) Remote indicating devices for measuring convergence, strain and loads on supports and in worked-out areas which have been filled with sand. Developments of suitable strain indicators. (b) Measurement of flow of sand concentration during stowing operations. (c) Control of liquid level in mixing cones or troughs during stowing operations. (d) Instruments to detect fires not visible and heated surfaces which are just in the starting stage.

From mining point of view, the instrumentation in electronics can be divided into three main parts as follows: (i) Application of electronics to surface installations and operations. (ii) Application of electronics to underground installations and operations. (iii) Application of electronics to investigate different mining problems,

APPLICATION OF ELECTRONICS IN MINING ENGINEERING

(e) Investigation into nature of surface damage and subsidence by a gamma ray probe. (/) Development of electronic devices for quick analysis of mine gases and coal dust. (g) Borehole logging. (h) Detection of voids in stowed areas.
DRIVER |llNPUT SIGNAL?

The control can be achieved by using closed loop scheme which involves the 'concept of error'. Its essential features are: (a) accuracy, (b) speed of response, (c) the stability or damping. These factors have to be reconciled in order to achieve correct operation. Figure 1 shows a block diagram of a complete closed loop scheme.

1 AMPLIFIERS

POWER SOURCE

1 PROCESS

Position of Drum Automatic Sensing Device Control Feedback Direct observation of results FIG. 1

(#) Detection of flaws in mining equipment, i.e., non-destructive testing. 4.0. Control Techniques In industries carrying heavy capital overheads, e.g., mining industry, significant reduction in cost and increased productivity can be obtained by using improved control systems. The major benefits thus obtained are : {a) Dependance upon human judgement is eliminated, thus allowing a more consistent output and less likelihood of accident or shut-down due to maloperation. (b) Improvement in the quality of production. (c) Cost of power per tonne of output can be reduced by greater efficiency in the use of power. (d) Reduction in labour force, thus increasing productivity. (e) Better working condition due to the shifting of the operator away from the possible areas of danger and dangerous atmosphere,

The choice of control components is governed by the following considerations which should be taken into considerations by the designers : (a) The assessment of the capital cost, running cost and profits. (b) The time taken in developing the control system. (c) The type of control which in turn is determined by the basic specification for the equip'ment. Some of the possibilities of applying the control system in the mining industry are as follows : (a) Photocells may be used for the position or level detection of cages or skips or lifts in winding. The difficulties of power supply and lamps for photo-elastic equipment can be overcome by using lower power gamma-rays. A static proximity switch with or without a magnet can also be used. (b) A selsyn transmitter and receiver unit may be used for the remote indication of shaft depth on a miniature depth Indicator.

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APPLICATION OP ELECTRONICS IN MINING ENGINEERING (c) Tachogenerators or other devices may be used for speed control. (d) A pressure-operated -device may find application at the coal face or for weight measuring pockets in case of skip winding or mine cars. A number of devices using strain gauge principle can be developed. However, it will be better to develop devices based on. the principle that when a magnetic material is mechanically stressed its permeability changes and rMS can be arranged to change the inductance in a magnetic amplifier. This can operate a relay or the next amplification stage. To reduce interference from cables in the mine shaft a high output with low impedance is desirable. To make intrinsically safe devices, transistors and silicon-controlled rectifiers will have to be used. Electronic controls may find "great use in controlling coal wagons in a coal preparation plant. In industrially advanced countries, automation has enabled automatic loading, hoisting and unloading of skips and cages. Manless coal faces are now becoming common. . The application of different control systems in mining industry is only possible by a team-work involving Scientists from different branches such as electronics, mechanical, mining. In a large mechanised mine, it is necessary for the manager to know immediately a breakdown in the production and transport system which may involve a breakdown in any part of the mine. Other items concerning which the manager should know immediately are: (a) the indication of machinery percentage loading, (b) indication of water .pressure in a system useful for both pumping or:; fire fighting or dust suppression, (c) indication of bearing temperatures or machinery, i.e., fans, conveyors, pumps, etc. (d) indication of air pressure, air flow in auxiliary fan installations underground, (e) indication of percentages of gas underground, etc. Besides these, there are many other items of information which the mine management wants to know at a central control room. Prompt action can be taken on receipt of these informations and this is an asset to production and a vigilant guard against dangerous occurrences. For transmitting these signals, which may number nearly 200 in a large mine, a single core cable transmitting signals of different frequencies may be used. This system will require (a) a transmitter of fixed frequency, (b) a single core cable, and (c) a receiver of fixed frequency response. The system can be designed to accommodate 250 channels using only a three volt battery. The values of frequencies may range Between 70 kilocycles per second to 130 kilocycles per second. A remote control may be used to indicate (a) v/ater level and bearing temperature of pumps, (b) fire damp content of the atmosphere at the pump house and thereby eliminating the necessity for a pump attendant. By using electronic equipment, it is possible to know (a) the position of a coal-cutting machine at any instant and also whether cutting or flitting is going on, (b) the length of the face cut by the machine, (c) machine starting and finishing time. The use of water flow alarms, suitably sited, will give immediate warning of the excessive use of water, indicating a burst pipe. The use of air flow indication in auxiliary ventilation will give immediate warning when the velocity falls below a prescribed value. In pneumatic stowing, as soon as the pressure on the outlet side of the stower exceeds a certain value there is likelihood of the stones jamming in the pipes. To avoid such pipe jams, it is necessary that the operator should keep a watch on the pressure gauge and as soon as the pressure exceeds the prescribed limit, the flow of material in the stower is stopped or reduced. This can be controlled by an electronic device.

APPLICATION OF ELECTRONICS IN MINING ENGINEERING with large amount of electrical drudgery associate with: (a) wages arid salaries calculations; (b) coal and coke sales accounting and allied marketing statistics; (c) materials and supplies accounting; and (d) costs and nominal accounting and statistics for different collieries. Some of the operational research problems involving critical path analysis and linear programming may be solved by computers. 6*0. Use of Isotopes 6.1. Determination of Ash Content of Coals: By measuring the degree of absorption or reflection of gamma-rays, if is possible to determine the ash content of coal. It is also possible to separate high ash coal and low ash coal on the running belt. The absorption of gamma-rays of lower energy depends on the chemical composition of the absorber. As coal consists of elements of lower atomic number and the ashes consist of elements of higher atomic number it is possible to deduce the ash content of the coal from the degree of absorption under constant surface weight (mass per unit surface). 6.2. Determination of Water Content of Coals: The fast neutron of water-containing compounds are more strongly retarded into the socalled slow neutrons, than in any other material. The number of slow neutrons formed is therefore dependent on the humidity content of the coal. Here also absorption or scatter of neutrons may be used to know the moisture content. 6.3. Counting. . Device- for Mine Cars or Wagons: If a gamma-ray'"unit is placed on one side of the track and acreceiving unit is placed on the other side, the gamma-ray will be interrupted by each passing mine car for a short period. This interruption can be used to-control a counting mechanism. This type of absorption mechanism

At Julia mine, Holland (1948), photo-electric cell device was used in the pneumatic stowing system with great success. The stowing material from a bunker was fed by means of a rotating table on to a belt conveyor which carried it to the pit top and discharged into a pipe leading down the shafts. The running of the belt and the rotating table was controlled by a photoelectric cell device which could be stopped automatically when it became necessary to avoid over-filling or blockage of the pipe range. The technique of atomic device to weigh in air was described to the International Conference on the atom in Geneva on 19 August 1955 by Mr. G. E. Crompton of the United States of America, Atomic Energy Commission, in which atomic radiation was being used in Hawaii to weigh sugar in the air as it falls freely from a conveyor belt. In this technique, high speed gamma-rays, released by atomic disintegration, are directed edgewise through a falling stream of sugar. The rays are bent by the sugar and the amount of bend is registered as weight in a counter. It seems quite feasible that similar atomic device could be adopted in hydraulic sand stowing or pneumatic stowing system in mines with a view to weigh the falling stowing material while in air at a suitable place in the system. The same idea could be extended to weighing coal before being filled in mine cars or railway wagons. 5.0. Use of Computers

Analogue computers may be used in mining and mine winder control system calculations. The computer will avoid many of the approximations inevitable in mathematical analysis and it will save considerable design engineering time and will allow more alternative systems to be investigated. A digital computer may be used for optimising mine winder horsepower calculations. Computers may find application in connection

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APPLICATION OF ELECTRONICS IN MINING ENGINEERING 8.0. References

can also be used to distinguish empty and full mine cars. The quantity of coal carried by a conveyor can also be measured. 7.0. Conclusion Automation in Indian mining industry has got to be introduced with reserve. In the national interest it is necessary to make full use of the modern knowledge to increase productivity and safety in Indian mines. In this respect the mining industry needs the help of electronic engineers to develop suitable instruments and control systems. The authors take this opportunity to thank the organisers of this seminar in C.E.E.R.I., Pilani, for inviting them to present this paper.

1. Swanzig, Walter, "Safety measures for electrical equipment in gassy minesI. Mechanisation of minesSymposium," Published by journal of Mines, Metals and Fuels, p. 467, 1962. 2. Indian Mines Regulation. 3. Hardt, L., "Die anwendung radioaktiver isotope in Bergau," Gluckaug 92 (25/26), pp. 761-62, June 23, 1956. 4. Starkey, W. A., "Electronic line signalling indicating equipment," IMMA, Vol. 14, No. 3, p. 23. 5. Mills, L. J., "Mechanisation, remote control and automation at the face," The Mining Engineer, No. 29, p. 422, February 1963. 6. England, J. & Simpson, H., "Electronic data processing," The Mining Engineer, No. 50, p. 128, November 1964. 7. Boyfield; L. R. & Janes, G. V., "Use of remote indication systems in colliery management," The Mining Engineer, No. 48, p. 703, September 1964.