www.centennialcoal.com.au

Booster Fans Angus Place Colliery

BJ Cutting

Manager of Electrical Engineering Angus Place

Centennial Angus Place

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Scone

Rylstone

Mudgee

Muswellbrook

Singleton

Maitland

Newcastle

Lithgow

Gosford

SYDNEY Katoomba

Berrima Wollongong Port Kembla

Kiama Moss Vale

Angus Place

Introduction

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• Mine established in 1978 • Mining the Lithgow seam • No history of methane or spontaneous combustion in Lithgow

Seam • Currently developing the Angus Place East Area which is an

expansion of Angus Place workings to 2031 • Planned production averages 3.5 Mtpa with longwall extraction • New Angus Place East ventilation facilities currently being

constructed. • Shaft No.1 due for commissioning in January 2015 • Current ventilation into Angus Place East was not sufficient to

support anticipated mining operations.

Process

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• It was identified that a Booster Fan would be required to provide adequate ventilation to the Angus Place East area until the completion of the new ventilation shaft no.1.

• Angus Place investigated what fan options where available within the industry that would suit the Angus Place short term application. (6-9 months)

• Identified 5 possible locations where the Booster Fans could be installed.

• Ventsim software was used to model the 5 selected Booster Fan locations.

• The decision was then made to install the Booster Fan in an intake airway not a return airway like other Booster Fan installations.

Booster Fan Locations Investigated

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

1 2 3 5

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Mine Plan

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Current Angus Place Workings

Future Angus Place East Workings

New Upcast and Downcast Shafts

Booster Fan Location

Process

• Angus Place conducted a risk assessment to identify the risks associated with a booster fan installation.

• Key Outcomes from the Risk Assessment. – Legislative requirements.(Design and Item Registration) – Organise meetings with key stakeholders.

• Department of Trade and Investment • Fan Manufacturers

– Develop a functional specification for the operation of the Booster Fan.

– Short timeframe for the Booster Fan Installation. – Additional work required outside the Booster Fan scope.

(ventilation devices)

• Visited other mining operations with in service booster fan installations to assist with the equipment selection process.

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Meeting with Department of Trade and Investment

• To obtain an understanding of how the department viewed a Booster Fan Installation in an intake airway and to make the process as smooth as possible.

– Could we treat it like a conveyor installation? Not a Booster Fan installation.

– Was there a requirement to apply for Design and Item Registration?

– Was it a High Risk Activity? – How would the department see the registration process moving

forward. – Was there anything that they could see being a show stopper?

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Equipment Selection

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• 3 x 110 kW Clemcorp axial fans in parallel • Ability to run either 2 or 3 fans in parallel due to fitment of self

closing doors in each fan duct – Eliminates recirculation in the event of a single fan failure

• Fans used extensively in underground metalliferous mines as booster fans.

• Nickel Brass alloy impellers and mild steel ducting. • Modular design ensures quick and simple installation.

Existing Fan Installation in a Metaliferous Mine

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Brass Nickel Impeller

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Positives - Preferred Option

• Reduced risk compared to an installation in a return airway. • Legislation requirements.

– Less departmental requirements ? (was the thought process)

• Easier installation – Access restricted in the belt road. – Parallel Installation. – No loss of production.

• Reduced pressure across the coffin seal.

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Negatives - Preferred Option

• Restricted access around Booster Fans – Vehicle access through double ventilation doors. – Process to get larger pieces of equipment through double

doors. – People and machine movement around and past Booster Fans.

• Airborne dust – Along 910 travelling road. – Migrating into 1000 district production units.

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Functional Specification

• If the main vent fan stops the booster fan is to stop immediately. • If any fan selected to run stops, all other booster fans stop. • If the booster fans stop the C910 conveyor is to be inhibited. • Environmental monitoring of CH4 and CO, if levels are detected

above the pre-set values all booster fans stop. • Any failure of ventilation inbye or outbye of the booster fan

installation, will cause all booster fans to stop. – Stopping Failure – Access or by-pass doors not in their correct position.

• If ventilation pressures are outside of the intended tolerances all booster fan are to stop.

• If the booster fans stop all power inbye of booster fans is turned off.

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Functional Safety Assessment

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Booster Fan Setup

• Bypass Doors open if the Booster Fans are stopped – Proximity sensors to monitor position of bypass doors and machine

access doors.

• Vibration and Temperature monitoring on all fans • CO and CH4 monitoring inbye and outbye of fans • Differential pressure monitoring across

– Fan Bulkhead – Coffin Seal – 19C/T 303 District

• Fans set to trip on any one failure of system components • Monitoring alarms in control room

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Booster Fan Setup

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BYPASS DOORS

D

D

Belt Road

Return Road

PNEUMATIC ACCESS DOORS

COFFIN SEAL

Booster Fan Monitoring

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PROXIMITY SENSORS

D

D

Belt Road

Return Road

PRESSURE MONITORING

CO & CH4 MONITORING

Fans Installed at Angus Place

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Bulkhead Self Closing Fan Doors

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Bypass Doors & Pneumatic Machine Access Doors

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PNEUMATIC MACHINES

ACCESS DOORS

VENTILATION BYPASS DOORS

Potential Hazards Identified in Risk Assessment

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• Booster Fan not turning off when Main Fan stops • Inability to conduct maintenance caused by insufficient access

around Booster Fan • Fire on Booster Fan • Damage to Bypass Doors • Insufficient air reaching Booster Fan due to failure of

Ventilation Control Device outbye of 910N • Complete failure of Booster Fan • Partial failure of Booster Fan • Increased dust caused by increased air velocity in 910N • Noise generated from booster fans

Citect Display / Remote Monitoring

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Booster Fan Starter

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Booster Fan Starter

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Commissioning

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Electrical Commissioning Sheet 0 Fans 1 Fan 2 Fans 3 Fans Settings (3 Fans Opperational) Reading Expected Actual Expected Actual Expected Actual Expected Actual Setting Type Setting Value

Bypass Doors Open Open Closed Closed Closed Closed Closed Closed Access Door 1 (outbye) Closed Closed Closed Closed Closed Closed

1 of 3 Closed Closed

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

Ventilation Survey

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Location

Ventsim Q Vensim P Measured V Measured Q Measured P Ventsim Q Vensim P Measured V Measured Q Measured P Ventsim Q Vensim P Measured V Measured Q Measured P

910N 4 - 6 C/T 14.98 65 1139 62.78 77 1600 91 2250

910N 16 - 17C/T 16 61 690 59 750 @ 17 C/T 72 970 4.6 73.6 1110 85 1362 4.85 77.6 1260

910N 35-36 C/T 15.5 49 83 45 100 @ 35 C/T 58 117 3.6 55.8 125 69 165 3.9 60.45 150

910 0-1C/T 3 hdg 15.36 78 1188 74 89 5.9 90.624 102 6.2 95.232

910N Regulator 9.6 82 78.7 92 9.8 94.08 104 10 96

910N Coffin Seal 9 1148 1270 7 780 770 5 350 490

82 91 890 1290 111 2010 2020

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900 7 - 8 C/T 15.51 71 460 71.3 400 @ 8C/t 66 395 4.1 63.591 350 60 320 3.85 59.7135 270

LW Face 34 32 29

303 19C/T 1727 1750 1500 1400 1255 1240

Main Fan 220 223 227

303 regulator 77 960 970 740 700

No Fans Bypass Open 2 Fans Running 3 Fans Running

Fan Bulkhead (D/D Closed)

Fan Bulkhead (D/D Open)

Item Registration

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Plant Registration - Exemption

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Start-up Sequence

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Acknowledgements

• Shane McClure & Scott Wyborn - Centennial Coal.

• Clemcorp Australia. • Simon Fulton & Grant Waring – ATF. • Mike Taylor – Advitech. • Marcus Punch.

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www.centennialcoal.com.au

Thank You