EPA
          Urosed States
          Environmental ProStsction
          Agency
            Industrial Environmental Research
            Laboratory
            Cincinnati OH 45268
FPA fiDO 7 78 080..
M.
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                RESEARCH REPORTING SERIES

Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:

      1.  Environmental Health  Effects Research
      2.  Environmental Protection Technology
      3.  Ecological Research
      4.  Environmental Monitoring
      5.  Socioeconomic Environmental Studies
      6.  Scientific and Technical Assessment Reports (STAR)
      7.  Interagency Energy-Environment Research and Development
      8.  "Special" Reports
      9.  Miscellaneous Reports

This report has been assigned to the  INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and  development of,  control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.

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                                            EPA-600/7-78-080a
                                            May  1978
   TESTING PROGRAM FOR MINING COAL IN AN
           OXYGEN FREE ATMOSPHERE
                  Volume 1
                     by

              R. C. Taliaferro
          Island Creek Coal Company
         Holden, West Virginia 25625

                     and

                  Don Motz
  Cyrus Wm. Rice Division, NUS Corporation
        Pittsburgh, Pennsylvania 15220
             Grant No. 14010 DIM
               Project Officer

              Donald J. 0'Bryan
Industrial and Extractive Processes Division
     Office of Research and Development
           Washington, D.C. 20460
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
     OFFICE OF RESEARCH AND DEVELOPMENT
    U.S. ENVIRONMENTAL PROTECTION AGENCY
           CINCINNATI, OHIO 45268

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                                 DISCLAIMER


     This report has been reviewed by the Industrial Environmental Research
Laboratory-Cincinnati, U. S. Environmental Protection Agency, and approved
for publication.  Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection Agency,
not does mention of trade names or commercial  products constitute endorsement
or recommendation for use.
                                      11

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                                  FOREWORD
     When energy and material resources are extracted, processed,
converted, and used, the related pollutional impacts on our environment
and even on our health often require that new and increasingly more
efficient pollution control methods be used.  The Industrial
Environmental Research Laboratory - Cincinnati (lERL-Ci) assists in
developing and demonstrating new and improved methodologies that will
meet these needs both efficiently and economically.

     This report is a systems evaluation of the concept of applying
an oxygen-free atmosphere to active deep coal mines.  The purpose
of the program was to demonstrate that miners wearing life support
systems can satisfactorily operate conventional mining equipment and
mine coal.

     The successful application of this concept could eliminate dust
inhalation and fire and explosion hazards, reduce mine drainage, and
eliminate the need for rock dusting and the use of special explosion-
proof equipment.  Where mines produce large quantities of methane
gas, capture and sale of the gas would be possible.

     This report will provide key information to those interested in the
feasibility of mining in an oxygen-free atmosphere or converting
an existing mine to oxygen-free operation.  For further information
contact the Resource Extraction and Handling Division.
                              David G. Stephan
                                  Director
               Industrial Environmental Research Laboratory
                                Cincinnati

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                              ABSTRACT

     A systems evaluation was undertaken to demonstrate the ability of
miners wearing life support systems to operate conventional mining equipment
and to mine coal at a test section in an active ventilated mine.  Their
ability to operate mining equipment and to perform other in-mine tasks was
successfully demonstrated.  No major difficulties were encountered in
performing these tasks and the miners reported they had never been that
comfortable before when working in a mine.

     Four life support systems, one conventional section of mining equipment,
an office building and a dedicated test face in an active ventilated mine
were used in the project.  Minimum modification to the mining equipment was
required to receive and operate the life support system.

     The life support system provided cool, clean air for the miner and did
not hamper his ability to work.  The system was adequate to demonstrate the
miner's ability to mine coal while wearing a life support system.  However,
mechanical failures in the chiller and rebreather module were experienced.
Additional work to develop a totally reliable life support system and
further testing under ventilated conditions are required before testing in
an oxygen free atmosphere.

     Due to the size of the Appendices, they have been published in a separate
volume, available from the National Technical Information Service (NTIS),
5285 Port Royal Road, Springfield, Virginia,  22161.  A list of the Appendices
has been included in the contents of this volume.

     This report was submitted in fulfillment of Project No. 14010 DZM -
Phase  II between the Environmental Protection Agency and Island Creek Coal
Company.  Also participating in this project was the Cyrus William Rice
Division of the NUS Corporation.
                                     IV

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                               CONTENTS
Foreword	   iii
Abstract	    iv
Figures	   vii
Acknowledgments  	    ix

     I.   Introduction 	     1
    II.   Summary	     3
   III.   Conclusions  	     5
    IV.   Recommendations  	     7
     V.   Project Organization 	     9
    VI.   Acceptance Testing -
              Miner's Life Support System  	    14
   VII.   Personnel Selection  	    21
  VIII.   Mining Equipment Modifications 	    23
    IX.   Testing and Training -
              Miner's Life Support System  	    27
     X.   Test Site	    42
    XI.   Communications	    48
   XII.   In-Mine Tests -
              Miner's Life Support System  	    54
  XIII.   Water Analyses	    70
   XIV.   Demonstration Mine Design	    74
    XV.   Demonstration Mine Costs	    86

References	    88
Publications 	    90
Appendices

     A.   Training Manual
     B.   Operating and Maintenance Manual  - MSA
     C.   Operating and Maintenance Manual  - Cambion Dehumidifier
          Air Exchanger
     D.   Operating and Maintenance Manual  - Emergency Rebreather
     E.   Specifications - Miner's Life Support System
     F-   Specifications - Mining Equipment - Phase II
     6.   Specifications - Communications System
     H.   Phase II Office - Design Drawing List
     I.   Phase II Office - Construction Drawing List
     J.   Demonstration Mine - Design Drawing List
     K.   Specifications - Mining Equipment - Demonstration Mine
     L.   Water Analyses
     M.   Project Delays

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N.   Demonstration Mine Costs
0.   Suppliers of Communications Systems
                             VI

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                                 FIGURES
No.                                                                    Page
 1       Plot Plan - Pond Fork Mine	10
 2       Floor Plan - Office and Equipment Test Building	11
 3       Project Office and Equipment Test Building 	   12
 4       Wrist and Calf Seal  	15
 5       Component Parts - Mine Personnel Rebreather  	   16
 6       Mine Personnel Rebreather - MSA	17
 7       Mine Personnel Rebreather - Modified 	   29
 8       Mine Personnel Chiller-Condenser-A 	   30
 9       Mine Personnel Chiller-Condenser-B 	   31
10       Mine Personnel Undergarment  	   33
11       Mine Personnel Suit - Front	34
12       Mine Personnel Suit - Side	35
13       Mine Personnel Stretch Garment - Front 	   36
14       Mine Personnel Stretch Garment - Side	37
15       Mine Personnel Life Support System - Holding Helmet  	   38
16       Mine Personnel Life Support System - Portable Mode	39
17       Mine Personnel Life Support System - Rebreather Open 	   40
18       Mine Personnel Life Support System - Ready to Enter Mine ...   41
19       Location of Test Section in Pond Fork Mine	44
20       Test Section Ventilation Plan	46
21       Test Section - General  Arrangement	49
                                   VII

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                           FIGURES (Cont'd.)
No.                                                                     Page
22       Wiring Diagram - Miner's Life Support Helmet  	   52
23       Miners Ready to Enter the Mine	58
24       Miner and the Loading Machine	61
25       Miner Operating the Loading Machine  	   62
26       Miner Tramming the Shuttle Car	63
27       Miner Loading the Shuttle Car	64
28       Miner Operating Roof Bolter  	   65
29       Miner Tramming Roof Bolter	66
30       Miner Operating the Coal Drill	67
31       Location of Water Sampling Points  	   74
32       Water Analyses - Variations  	   76
33       General Arrangement - Demonstration Mine  	   78
34       Flow Diagram - Inert Gas System	80
35       Water Seal - General Arrangement 	   82
36       Water Seal - Section View	83
37       Water Seal - Elevation View	84
38       Flow Diagram - Water System	86
39       Instrument Diagram - Monitor and Interlock  	   88
                                   viii

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                            ACKNOWLEDGMENTS

     The excellent cooperation and technical assistance of K. W. Heising of
the National Aeronautics and Space Administration is gratefully appreciated.

     Messrs. Stonie Barker, Jr., W. F. Diamond, R. C. Taliaferro, and R. L.
Turner of Island Creek Coal Company, with their project associates
J. K. Rice, J. C. Troy, and D. J. Motz of Cyrus Wm. Rice Division, NUS
Corporation, directed and guided this Phase II equipment testing propram.

     The support and technical advice of the United States Bureau of Mines is
gratefully acknowledged.

     The support of the project by the Environmental Protection Agency, and
the excellent technical guidance provided by A. Cywin, E. P. Hall, and D.J.
O'Bryan, Jr., the Grant Project Officer, is acknowledged with grateful
appreciation.

     The cooperation of the District 17 office and of Local No. 1696 of the
United Mine Workers of America is gratefully appreciated.

     The excellent cooperation and contributions of V. Gartin and R. Adkins,
members of the local United Mine Workers of America assigned to the project,
is gratefully acknowledged.

     The assistance of R. Rocco, E. Prindle, and C. L. Leffer of Arrowhead
Products Division, Federal-Mogul Corporation; of W. Mausteller, C. H. Staub,
M. McGoff, and W. B. Miller of MSA Research Corporation; of J. Martin, J. Staud,
and P. Bennett of Motorola Communications and Electronics, Incorporated; of
J. T. Katelan of Pittsburgh Communications Service, Incorporated; of S. Lybarger
of Radioear Corporation and of F. J. Kaminski of Cambridge Thermionic Corpora-
tion is acknowledged with sincere thanks.
                                      ix

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                               SECTION I

                             INTRODUCTION

     The concept of applying an oxygen-free atmosphere to active deep coal
mines involved miners using life support systems to enable them to operate
mining equipment in a mine blanketed with an oxygen-free atmosphere.
Preliminary conceptual studies indicated the possible success of the
application in not only abating acid mine drainage but in eliminating both
dust inhalation and fire and explosion hazards from mines.  Other possible
benefits that could occur included the elimination of rock dusting and
the use of special explosion-proof equipment.  In the case of mines producing
large quantities of methane gas, capture and sale of this gas would be
possible.

     An in-depth feasibility study into this concept was conducted through
a Research and Development Grant No. 14010 DIM from the Federal Water Quality
Administration to Island Creek Coal Company titled "A Demonstration of a New
Mining Technique to Prevent the Formation of Mine Acid in an Active Deep
Mine - Phase I."  The report of the study titled "Feasibility Study of Mining
Coal in an Oxygen-Free Atmosphere," August, 1970, verifies the original
concept.  Off-the-shelf technology and equipment is available and no major
technical pitfalls were foreseen.

     The guidelines adopted for the feasibility study were as follows:

1.   Maximum use was to be made of available equipment with no or minor
     modifications.

2.   A demonstration mine was to be designed to use nitrogen, nitrogen plus
     methane, or all methane atmosphere in the mine limiting the oxygen
     content to a maximum of 0.1% v/v.

3.   The demonstration mine was to be located adjacent to an existing active
     mine but not physically connected to it so that the coal handling and
   .  preparation facilities of the active mine could handle the coal produced
     in the demonstration mine.

4.   A refuge station ventilated from the outside with normal atmosphere
     was to be located in the demonstration mine near the working face.

5.   Conventional  rubber tired, battery operated mine tractors were to be
     used.

6.   The demonstration mine should be a one-section mine using conventional
     mining equipment working one shift per day.

                                      1

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     The Phase I feasibility study report recommended the purchase and
testing of prototype equipment in an active ventilated mine and the design
of a demonstration mine for testing the oxygen-free concept.  This program
was initiated to carry out the recommendations of the Phase I feasibility
study using the guidelines established for the Phase I study.

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                                SECTION II

                                  SUMMARY

     The purpose of the program was to demonstrate that miners wearing life
support systems can satisfactorily operate conventional mining equipment
and mine coal.  This was successfully demonstrated.  Two miners equipped with
life support systems operated all pieces of conventional mining equipment
at a test face in an active ventilated mine and performed other in-mine tasks
such as cleaning ribs, setting timber, and repairing equipment.

     The specifications developed in the Phase I program were used to select
the suppliers of the communication system, the rebreather, the chiller, the
life support suit, as well as the mining equipment which included a cutting
machine, a coal drill, a roof drill, a shuttle car, and a loading machine.
The selected suppliers of the basic life support and communications systems
are listed in Appendix 0.

     The chiller module of the life support system operated on 110V-AC power
and contained a transformer which provided 24V-AC power for the rebreather.
A 440V-110V transformer was mounted on the mining equipment and a 110V outlet
was provided to operate the chiller module.  Support racks for the rebreather
and the chiller modules were fastened to the mining equipment.  A mine height
of 48 inches was used and every attempt was made to keep the overall equipment
height below 36 inches.

     The life support systems were tested in the Office and Equipment Test
Building built for the project and two miners were trained in their use.
Here rebreathers and chillers were also fitted to the mining equipment prior
to taking the equipment into the mine.

     The test face provided in the active adjacent mine required the building
of stoppings, air curtains, a track crossover, a side-belt loading station,
the setting of timbers, the removal of gob, and rock dusting in order to
insure a safe test face that conformed to existing mining regulations.  The
major portion of this work was performed by the two miners assigned to the
proj'ect.

     The radio transmitter was installed at the mine mouth and the antenna
cable hung in the mine to provide radio communications between the test face
and the maintenance shop of the mine.   This communications system proved
highly effective and requires serious consideration for future use in coal
mines.

     After developing the test face, the individual miners, wearing a life
support system and carrying their helmets, were taken to the test section

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where the helmet was donned and they proceeded to operate the mining equipment.
Each operation was documented on movie film and still photographs.  Some
problems did develop which caused the premature shutdown of several tests.
In every case, the miner had no difficulty operating the respective pieces of
machinery involved.  In no way did the life support system prevent him from
performing his duties.

     The project, originally scheduled for eighteen months, took thirty months
to complete.  The 1969 Health and Safety Act changed the specifications on the
mining equipment causing an increase in delivery time from fourteen to forty
weeks on some pieces of equipment.  The miners' strike caused a six-week delay.
Delays in receiving approval to take nonpermissible equipment into the mine
and in choosing miners for the project were also experienced.

     Due to these many delays, the actual in-mine test period was limited to
six weeks.

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                                SECTION III

                                CONCLUSIONS

     The adapting of a prototype life support system to conventional mining
equipment and testing it in a ventilated coal mine has developed the
following conclusions:

1.   The life support system was adequate to demonstrate the concept
     of miners using life support systems while mining coal.  However,
     the overall reliability of the system needs to be improved.

2.   The communications system employing FM transceivers, provided reliable
     communications throughout the test period and did much to expedite the
     project by providing direct communication from the test face to the
     mine mouth.  However, the noise from the mining equipment, when it was
     in operation, made it extremely difficult to communicate with others.
     A paging system, to alert the miner of incoming messages, would be
     helpful.

3.   The hearing aid proved to be a reliable method of sensing in-mine noises.
     However, it created nondirectional hearing which presented problems in
     locating the source of the noise.

4.   The helmet did not interfere with the miner's vision, nor did it present
     problems when he was required to bend over.  The visor remained rela-
     tively clear of dust even when there was a heavy concentration.  There
     were some complaints regarding the weight and it is suggested that a
     lighter unit would be more desirable.

5.   The emergency rebreathing unit proved to be reliable when operated by
     personnel who were properly trained in its use.

6.   The life support suit performed in a generally satisfactory manner.
     However, the mechanical  chiller was highly susceptible to vibration
     damage.  Also, the overall  size and weight of the rebreather and chiller
     presented problems in carrying and mounting it on the mining equipment.

7.   Modifications of the mining equipment to accommodate the life support
     system were minimal.  However, the available locations on the equipment
     for mounting the life support system, in some cases, resulted in limiting
     the vision of the equipment operator and exposed the life support system
     to possible damage due to contact with the roof and ribs of the mine.

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8.   The life support system did not appreciably hinder the miner and this
     indicates that average present day miners, who are skilled in operating
     modern conventional equipment, continuous miners, or longwall mining
     equipment, have the skills necessary to understand and operate the life
     support systems.

     During the test periods miners were able to operate the units of mining
     equipment and perform routine maintenance tasks as well as setting roof
     support timbers and shoveling along rib lines.

9.   The blanketing gas system and the controls for a demonstration are
     estimated to cost $1,154,00..  An additional capital investment of
     $734,760 is required for mining equipment, life support systems, and
     support facilities.  An annual operating cost is estimated to be
     $778,800.  Credits received for the coal mined under this program would
     be applied in reducing the costs.  (Costs are based on 1973 levels.)

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                                SECTION IV

                              RECOMMENDATIONS
     The life support system tested in this program adequately demonstrated
the concept of miners using life-support systems while physically mining coal,
The system, however, should be refined in order to improve its acceptability
and reliability and to further demonstrate its capabilities.  The following
recommendations are therefore extended:

1.   The helmet of the life support suit, while not presenting any major
     problems, proved to be bulky and cumbersome.  It is recommended that
     this unit be redesigned to make it lighter, less bulky and more
     comfortable.

2.   The emergency rebreathing apparatus proved adequate as a life support
     system.  However, there was a slight delay in activating the unit which
     could present problems under actual emergency conditions.  It is recom-
     mended that further evaluations be made to determine if the unit is too
     difficult to activate under the emergency conditions which must be
     anticipated in an oxygen-free mine.  It is further recommended that
     alternate types of emergency rebreathing apparatus be tested and
     evaluated.

3.   The chillers were large and difficult to locate on the mining equipment.
     Several mechanical failures were experienced in the use of these devices.
     It is recommended that a review be made of their design and that improve-
     ments be made to eliminate the source of the mechanical failures.   In
     this experimental phase, the cooling equipment that was used presented
     a minimum of interference in adapting it to the existing mining machines.
     However, alternate cooling systems, which may involve some redesign of
     the chiller units, appear to be desirable.

4.   The communications system performed adequately, but it was difficult to
     use while the machinery was running, because of the noise level.   It is
     recommended that a paging system,  to alert the miner of incoming
     messages, be incorporated into the system.  The standard hearing aid
     might also be incorporated into the radio circuitry to provide both
     hearing aid and radio reception in both ears.   It is further recommended
     that a second microphone and hearing aid be provided to simulate stere-
     oscopic hearing.

5.   The bulk and weight of the life support system, to some appreciable
     degree, detracts  from its acceptability.  It is recommended that
     alternate approaches to the life support system be investigated in an

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     attempt to reduce the weight and bulk which must be carried by miners
     in the portable mode.  These investigations may also provide greater
     flexibility of the system.  A smaller and more compact life support
     system, to be used in the portable mode, might be plugged into the main
     system located on the machinery; this would help achieve the above
     objectives in permitting greater mobility when used in the portable
     mode.

6.   During the redesign and adaptation of the life support system to mining
     equipment, the potential use of the system for mine rescue work should
     be recognized.  It is recommended that this application be given major
     consideration in deciding the ultimate uses of a successful life support
     system of this type.

7.   It is recommended that a test mine, dedicated exclusively to the use of
     this project, be constructed along with the associated office buildings
     and other outside facilities required for this type operation.  Such
     an installation would provide for the testing of all phases of work
     related to testing the life support system.  Upon the completion of the
     installation of a test mine, the complete life support system should be
     reviewed, redesigned and modified for testing to further enhance its
     capabilities and reliability, which initially appeared questionable.

     Testing of the life support system should be conducted in the test mine
for a minimum of twelve months under ventilated conditions.  This should
provide adequate time for the necessary modifications and the development of
a completely reliable system.

     fonce a life support system considered completely reliable is developed,
the inert gas systems should be installed in the test mine.  The life support
system would then be tested in an oxygen free atmosphere, with miners actually
producing coal.  This phase of the program should be conducted for a minimum
of twelve months to fully insure that the system is safe and operable and
economically justifiable.
                                     8

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                                 SECTION V

                           PROJECT ORGANIZATION

     This project is Phase II - Component Evaluations of a four part program
being conducted under a Research and Development Grant No. 14010 DIM from the
Environmental Protection Agency to Island Creek Coal Company to demonstrate
that mining coal in an oxygen-free atmosphere will prevent the formation and
subsequent discharge of acid mine water into streams and other water courses.
The Phase I Report indicates that life support systems similar to those used
by NASA in the space program can be adapted to conventional mining techniques.
Technology is available to develop with a minimum of research a suitable
life support system for use by coal miners and communications can be main-
tained between the miners.

     The objectives of the program are to purchase, test, modify, and retest
prototype equipment and to train a selected group of miners in the use of
this equipment.  This testing is to be conducted in a special test section in
an active ventilated mine set aside for the exclusive use of the test crew.
Mining equipment is to be operated under the direction of the test engineers
by two miners equipped with life support systems.  The final results of this
program were to be a tested, proven, and reliable life support system for use
in an oxygen-free demonstration mine, as well as the detailed design and the
estimated cost for the construction and operation of a demonstration mine.

     In order to accomplish these objectives, the project was broken down
into several well-defined steps which were as follows:

1.   The specifications in the Phase I Report for the life support and
     communications systems were sent out to various suppliers for quotations
     as to price and delivery.  Island Creek's standard specifications for
     mining equipment were sent out for quotations for a cutter, a loader,
     a shuttle car, a roof bolter, and a coal drill.  These quotations were
     received, evaluated, and purchase orders were issued.

     A plot plan (Figure 1) for the adjacent Pond Fork mine showing the
     location of the test facility was developed.  Preliminary designs for
     the Office and Test Building were reviewed and detailed design drawings
     were made.  Figure 2 is the floor plan of the Office and Test Building.
     See Appendix H for a listing of the design drawings.  A prefabricated
     metal shell building (Figure 3) was chosen as the most economical  type
     of structure to use.

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MINE EXHAUST-
FAN HOUSING
                                                             OFFICE
                                                             •TRAILER-WAITING ROOM
                                                             TRAILER-LAMP HOUSE
                                                              RANSFORMER STA.
                                                               OIL HOUSE
                                                               MINE  ENTRY
                                  OFFICE 8 EQUIPMENT
                                    TEST BUILDING
     TRANSFORMER
        YARD
           SEWAGE
        TREATMENT  PLANT
                                       FIGURE  1
                               PLOT PLAN  OF POND FORK
                                    MINE  FACILITIES

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         LOCKER
          ROOM
       8  STORAGE
      LAUNDRY
       ROOM
          OFFICE
•WINDOWS
(TYPICAL)
              EQUIPMENT  TEST
                   AREA
              (CRUSHED SLAG)
    CONCRETE  WALKWAY 8 FLOOR
                        t
                  ~7
         EQUIPMENT
          SERVICE
OXYGEN
STORAGE
                               EQUIPMENT
                                SERVICE
                                              CLASSROOM
                         FIGURE 2
                   FLOOR PLAN OF OFFICE
                AND  EQUIPMENT TEST BUILDING
                                                              SLIDING
                                                               DOOR
                                                              GARAGE
                                                               ENTRY

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IX)
                                               vT*-''      '   -  '
**t
                             •
                                                **'   •
                                                 -»•_;'. *^ >_•-

                                                                .   .•'.'
                           Project Office  and  Equipment Testing Building
                                            Fiqure 3
                                                                    .  ..'

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2.   Bids were received for the construction of the office building.  They
     were unexpectedly high and the drawings were revised to reduce the cost.
     See Appendix I for a listing of the construction drawings.  The building
     was constructed using the revised drawings.  As the mining equipment was
     received, it was stored for future use.  Preliminary review and testing
     of the miners' life support system was conducted at the laboratories
     of the suppliers.

3.   Modifications to the mining equipment were undertaken to adapt the
     chiller and rebreather modules of the miners' life support systems to
     the equipment.  Preliminary testing and evaluation of the life support
     system was conducted in the Office and Test Building and two miners were
     trained in its use.

4.   A test face was established in the adjacent active ventilated mine using
     the two miners assigned to the project to do the major portion of the
     work.  This involved removing the gob from the area, bolting the roof,
     and rock dusting the area, as well as constructing a track crossing and
     a belt loading station.  All this work had to be completed prior to
     testing in the mine.

5.   In-mine test programs were conducted, taking each miner individually
     into the mine while wearing the life support suit and carrying the
     helmet.  At the test face, the helmet was donned, the life support
     system was put into operation, and the miner operated the various
     pieces of the mining equipment.  Additional testing was conducted with
     both miners in the suit at the same time.

6.   The necessary information was developed for the design of an oxygen-free
     demonstration mine.  Suitable drawings were prepared and an estimate
     of costs to construct a demonstration mine was developed.
                                    13

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                                SECTION VI

                            ACCEPTANCE TESTING
                       MINERS' LIFE SUPPORT SYSTEM

     As a result of the bid analysis for the various pieces of life support
equipment, Arrowhead Products Division, Federal-Mogul Corporation, Los
Alamitos, California, received the contract for four life support suits,
including the helmets.  MSA Research Corporation of Evans City, Pennsylvania,
received the contract to design and construct five rebreather and chiller
modules, including the tether system.  Motorola Communications and
Electronics, Incorporated, Parma, Ohio, received the contract to supply the
radio communications system and the Radioear Corporation of Canonsburg,
Pennsylvania, were the consultants on the hearing aid.  All units were to
be built according to the specifications established in the Phase I Report.
A meeting was held with all the suppliers present to establish responsi-
bilities and interfaces between them.

     Arrowhead Products Division, Federal-Mogul Corporation, was to supply,
initially, two life support suits; the remaining two to follow once appro-
priate sizes had been determined for the union personnel assigned to the job.
One suit was sized to fit Mr. R. L. Turner, Project Mining Engineer, and the
other was sized to fit Mr. R. C. Taliaferro, Project Director.  The suit to
fit Mr. Turner was shipped to the MSA Research Laboratories so that they could
mate the rebreather system to the suit and test the complete system.

     In reviewing the suit specifications with Arrowhead, it was determined
that the rigid cuff and ankle seals called for in the Phase I specifications
could present problems and create objections by the miners.  As a result, the
decision was made to use a seal similar to storm cuffs on winter clothing
(see Figure 4).  All suits were to have this type of seal.

     MSA Research Corporation of Evans City proceeded with the design and
construction of a prototype rebreather and chiller.  During the design of the
rebreather, MSA determined that to meet the Phase I specifications for the
rebreather to provide oxygen  for eight hours normally and contain an addi-
tional four hour emergency supply, the unit would weigh over seventy pounds.
After reviewing this with  Island Creek and RICE, the specifications were
changed  so that the delivered system would provide oxygen for four hours and
the battery requirements were reduced from a two to a one hour duration.
These changes effectively  reduced the rebreather weight to approximately
fifty pounds.   Figure  5  shows the component parts and subassemblies used in
the rebreather  and  Figure  6  shows the unit as assembled by MSA.  This unit
was mated to Arrowhead's suit and preliminary tests were conducted in MSA
laboratories.
                                      14

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            Rubber Seal
Suit
    Wrist
  Suit
Rubber Seal
  Boot
                  Wrist Seal
                       Suit Pressure
                              Calf
                   Calf Seal




                  FIGURE 4
                      15

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Component Parts of the Mine Personnel Rebreather



                    Figure 5

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Mine Personnel Rebreather (MPRB)



           Fiqure 6

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     Mr. R. L. Turner of Island Creek Coal Company (Island) and Mr. D. J. Motz
of Cyrus Wm. Rice Division-NUS Corporation (RICE) visited the MSA laboratories
to inspect the system and to assist in conducting preliminary tests.  The
initial tests were disappointing as there were many leaks in the chiller
module.  The chiller module was a square unit constructed of soft copper
sheeting with a bolted flanged top.  The copper being soft made it impossible
to maintain an air-tight seal between the flange and the cover sheet.  This
required a complete redesign of the chiller unit resulting in a cylindrical
unit that proved satisfactory.

     Upon the completion of the redesign and construction of the chiller
unit, Messrs. Motz and Turner again visited MSA to test the system.  Once
again, the results were disappointing.  The system was still not air-tight.
In checking the system for leaks, it was determined that the adhesive used to
assemble the tethers was failing.  Flexing the tethers caused the adhesive to
break away from couplings and leaks would develop.  As a result, testing was
postponed while MSA approached the manufacturer to determine the suitable
adhesive for assembling the tethers.

     One bit of important information gained through these leaks was that a
leak on the suction side of the blower caused an intake of air into the
system and the suit to balloon excessively.  Leaks on the discharge side of
the blower caused the system to evacuate and the suit to cling to the man.
If the  suit balloons excessively, look for the leak in the return tether from
the suit to the rebreather, as this is the only part of the system under
negative pressure.  If the suit evacuates, the leak could be anywhere in the
system  except the return tether to the blower.

     After the tethers had been completely reassembled, using the new
adhesive, Messrs. Turner and Motz visited the MSA laboratories to test the
system.  When Mr. Turner donned the suit and the system was started up, odors in
the suit made it impossible to continue.  These odors were traced to the new
adhesive.   It was determined that in the future, repairs to the tethers
should  be  cured for approximately 48 hours and be purged with air before
being  used.  Otherwise, the adhesive odor would make it impossible to stay
in the  suit.  In the laboratory, the tethers were placed in a low temperature
oven and air-purged to hasten the evaporation of the adhesive.  Testing
continued  the following day.

     Mr. Turner donned the suit and it appeared that all leaks in the system
had been resolved and the system was air-tight.  At this point, two problems
developed.   One was that the  suit ballooned or appeared to be overinflated
and that every  time there was movement within the suit, the trapped air
would  cause the  helmet to rise on the head.  Bending over caused the helmet
to  rise above the eye  level.  A slight movement of the foot would cause the
helmet to  bounce  up and down  on the head.  This was quite annoying and a
problem that had  to be solved.

      The  second problem was  controlling the oxygen flow and pressure in the
system, as this appeared to  be the  cause of the over-inflation of the suit.
 Early in  the program,  the decision was made to use compressed oxygen to
maintain  a positive pressure in the system of one-half inch water column as

                                      18

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well as to supply the oxygen for breathing, with the suit acting as a breath-
ing bag.  It was felt that if the pressure criteria were maintained, there
would be adequate oxygen in the system for breathing.

     The initial pressure-sensing line was installed to control the oxygen
input at the suction side of the fan.  Under this arrangement, the regulator
was attempting to maintain a positive one-half inch pressure while sensing a
negative suction pressure of six inches.  This was an impossible situation
which caused the oxygen regulator to continuously dump oxygen into the
system.  Other points for controlling the oxygen input were investigated.
The discharge side of the fan presented problems similar to the suction side,
only in this case the discharge pressure of the blower would prevent the
regulator from operating.  The only logical place to control the oxygen flow
and sense the suit pressure was a sensing line directly to the suit.  An
experimental system was tested in the laboratory and seemed to perform
satisfactorily.

     A permanent pressure-sensing line was installed inside the return tether
from the suit.  The sample line terminated at the tether fitting located at
the suit, and exited the tether prior to the tether Quick Disconnect at the
breather.  A separate Quick Disconnect was provided to connect the sample
lines to the rebreather.  This scheme permits the sensing and control of
actual in-suit pressure.  Once this sample line was installed, it was found
that the regulator was unable to maintain the control pressure and it was
necessary to change to a lighter spring in the regulator.

     Once this was done, the regulator was able to maintain an in-suit
pressure of 0.4-0.6 inches water column.  A separate line inside the rebreather
injected the oxygen into the tether at the discharge of the blower.  The
sensing line in the return tether was purely a control line and did not deliver
oxygen directly to the suit.

     These modifications corrected the oxygen control problem by maintaining
the control pressure in the suit.  The problem of the trapped air within the
suit, causing the helmet to rise on the head whenever there was movement
within the suit had to be brought under control before the system would be
acceptable.

     During one of the discussions, it was suggested that an elastic stretch
garmet worn over the gas-tight garment may provide the elasticity required
to permit the gas within the suit to move freely about without causing the
heTmet to rise.  To initially evaluate this concept, the long underwear was
slipped over the gas-tight suit to confine the suit.  The helmet rise was not
as serious as it had been without the underwear.   It was decided to determine
what garments were available to provide this elasticity without requiring any
major tailoring costs.

     The investigation into several  possible suits to serve as a stretch
garment included such things as wrestling tights,  football  uniforms,  women's
knit tee shirts and stretch slacks as well  as the  standard  body stocking or
leotard, as it is more commonly called.   The stretch jersey,  slacks,  and a
leotard were purchased and tested.  Both systems controlled the helmet rise

                                   19

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problem.  However, the one-piece leotard proved superior.  The jersey and the
slacks combination gapped at the waist and created problems.  As a result, it
was decided to modify the leotard by installing a zipper in the front to make
it easier to put on over the gas-tight suit.

     Once the leotard had been modified, the complete, assembled life support
system was.tested.  The underwear, the gas-tight suit, the stretch garment,
and a standard miner's coverall made up the complete suit assembly.  The
system was pressurized in excess of seven inches water column.  Even under
this pressure, there was freedom of movement and no problem with keeping the
helmet on the head.  The leotard as the stretch garment proved successful
in controlling this helmet-rise problem.

     One of the remaining problems was to install some means of inflating the
system with ambient air prior to opening the oxygen valve and to provide a
gauge to indicate when the suit was at the control pressure.  During the
initial testing, it was observed that when inflating the suit to the control
pressure using oxygen, the initial oxygen concentration would exceed 40%.
This was unacceptable as the system should initially start out as close to
ambient air as possible.  The suit had to be filled with ambient air to meet
this criteria.

     In order to accomplish this, a pressure gauge was installed on the oxygen
control line to directly read the in-suit pressure.  In addition, a toggle
valve was  installed on the suction side of the blower.  When this toggle valve
was opened, the blower would suck room air into the system.  When the gauge
indicated  the control pressure had been reached, the toggle valve would be
closed and oxygen valve opened.  When the system was put into operation in
this manner, the oxygen concentration rose to approximately 25%.

     This  appeared to solve the control and start-up problems with the life
support system.  MSA completed the assembly of the remaining units and shipped
them to the mine for further study.
                                     20

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                                SECTION VII

                            PERSONNEL SELECTION

     The original plan proposed for the project in regard to the selection
of people to operate the mining equipment was to select the miners from the
work force at the adjacent Pond Fork mine.  Selection of personnel from the
work force at the adjacent mine would minimize any possible difficulties with
the local union.  Also, the men chosen were already available at the mine,
were already members of the local union, and were familiar with the conditions
existing at the mine.

     Selection of the miners for the project was critical since only two
miners were going to be used and they had to be able to operate each piece
of mining equipment.  This required experienced miners, with particular skills
not always available from every mine worker.  They had to be in reasonable
physical condition and be able to wear the life support gear without fear.
Their work records would be reviewed and each one would have to be judged a
dependable and reliable member of the work force.

     Before the men were chosen, however, certain criteria were established
for the men and the job.  Island Creek's labor relations personnel agreed
that the miners should be taken  from the local force at the mine, they
should remain on the project for the length of the project, and upon the
completion of the project should be allowed to return to their regular jobs
with no loss of their benefits, which includes such things as seniority, job
bidding, vacation and Christmas pay, and all compensation benefits.  They
would receive the top rate of pay for the underground miner as specified by
their current contract for the length of the project.  Upon returning to the
work force, they would revert to the same pay level they had before trans-
ferring to the project.  Since only two miners were being used, their
selection should be based on qualification only and not seniority.

     With these criteria, Island approached the District 17 office to the
United Mine Workers of America in Charleston, West Virginia, to obtain their
approval of the criteria and to obtain their permission to approach the local
union to seek their permission to post the jobs and ask for volunteers for the
projects.  The District 17 office offered their support, approved the job
criteria, and granted the permission to meet with the local  union.

     Island approached the local union officers, briefed them on the meeting
with the District 17 officers, reviewed the scope of the project and the job
criteria with them, and asked for their support and permission to ask for
volunteers from the work force.  Approximately three months  passed before any
action was taken by the local union to give Island Creek permission to select
the needed miners for the project.

                                     21

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     When permission was received, a letter asking for volunteers was posted
on the bath house bulletin board for five days according to the standard
contractural procedure.  Twenty three miners volunteered for the project
representing various ages, work backgrounds and abilities.  The work record
of each of the volunteers was reviewed to select two miners who met the
requirements of the project.

     Of the two men selected, one was 26 years old, had two years underground
mining experience, and was a qualified roof bolter, shuttle car operator,
and shot fireman.  The other was 40 years of age, had 20 years underground
mining experience, and was qualified to operate the loader, shuttle car,
coal drill, roof bolter, and cutting machine.  Both men had excellent work
records and after discussing them with the supervisory personnel at the mine
the men were notified of their selection.

     The younger man was assigned to the project to assist in modifying the
mining equipment to receive the life support system and to perform other
duties in the project test office.  The second man was assigned to the project
when the equipment modifications were complete and the equipment was ready to
be taken underground to establish the test face.

     The following is the letter that was posted on the bath house bulletin
board:

                             A       NO N
     As of this date, December 31, 1971, the management of Island Creek Coal
Company is asking for volunteers to participate in an experimental project to
be conducted at this mine.

     Qualifications will be minimal, but final personnel selection will be
made by management and according to project requirements.  At present the
project is anticipated to run for a minimum of six months, with further testing
to continue only if this phase proves feasible.

     This is strictly a volunteer operation.  Any personnel selected will be
expected to return to their present jobs pending completion of the project,
with their present rate of pay, and with no loss of seniority.  However,
while  participating in the project, personnel will receive top rate of pay
as outlined by the 1971 UMWA contract.  In addition, testing will be done on
the day shift  for the entire length of the project.

     If you have any interest in volunteering for the project, please sign
your name in the space provided below.

                    Thank you.
                                     22

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                               SECTION VIII

                          EQUIPMENT MODIFICATIONS

     Each piece of mining equipment for the project was delivered exactly as
though the machine was to be used in a standard mining operation.  No special
modifications were made to the machines before they left the factory.  At the
time the equipment was ordered, the anticipated need for the machinery at the
mine was such that the project was better served if project personnel would
modify and install the life support units on the equipment at the mine.  The
two major difficulties encountered when mounting the life support gear was
obtaining an electrical power supply for each unit and finding space available
for attaching the life support units to each machine.

     The life support unit operated at a different voltage than was normally
available on the mining machines.  The air conditioning unit, or chiller,
required a 115V AC source, and contained a 115V AC/24V AC transformer
which in turn supplied the 24V power for the rebreather.  If a 115V AC power
supply was available for the air conditioning unit, the rebreather power
supply would be solved at the same time.

     Each piece of mining eqipment had either a 440V AC or a 250V DC source
available for driving the life support units.  Ehe roof bolter, coal drill,
cutting machine, and loading machine all operated on 400V AC, while the shuttle
car operated from a 250V DC source.  To obtain the 115V AC from the alter-
nating current machines, additional wiring connected to the 400V AC line on
each machine was required.  This line must be energized whenever the machine
was energized to allow the life support unit to operate even when the machine
was sitting idle and nost just when the machine was actively working.  This
meant that each machine's power supply be taped directly from the electrical
panel.

     It was realized at the time that whenever this was done the permissibility
of the machine would be destroyed unless the proper modification procedures
were followed.  This would greatly increase the cost of these changes and
since the life support system was not permissible, the additional  expense did
mot seem justified.  If the nonpermissible life support system could be used
in the mine, there was no need for the mining equipment to be permissible.
The wiring changes were made in such a manner that the minning machinery could
be readily returned to its permissible rating with a minimum of effort.   In
addition, the Pond Fork operation is a nongassy mine and adequate rock dust
was applied, thus greatly reducing any fire or explosive hazards.   In general,
the modifications to the machines were minor and would not incur any hazard
to the mine personnel.  The modifications were made knowing  that though the
equipment would be nonpermissible it would still  be safe to  operate  at the
test face.  An inspection by the USBM personnel  confirmed this  and permission

                                      23

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was given to move the equipment to the underground test site.

     To provide access to the 440V AC in the electrical panel, a hole was
drilled througfi the panel cover plant to permit a 14 gauge, three conductor,
600 volt cable to pass through.  This cable ran from the panel to a 1 KVA
transformer where the power was reduced from the 440V AC to the 115V AC needed
for the air conditioning unit.  After leaving the 1 KVA transformer the 115V
AC terminated at a single grounded outlet located near the air conditioner
and easily accessible to the operator.  The operator could plug in the air
conditioner and rebreather whenever he so desired.

     The shuttle car presented a little different installation problem as it
operated on 250V DC and the rebreather operated on 24V AC power supplied from
a 115V AC/24V AC transformer in the air conditioning unit.  Here is was
necessary to find a means to change the direct current to alternating current,
or to find another way of using the direct current to operate the rebreather.
A special air conditioner operating on 250V DC was purchased for use on the
shuttle car and unlike the mechanical air conditioning unit, it did not provide
the 24V AC power to operate the rebreather.  A separate power supply for the
rebreather was required.  A small 1 KVA motor generator set was installed for
this purpose.  The 250V DC drive motor operated a 115V AC generator which
supplied power to a 115V AC/24V AC transformer which in turn supplied the
power for the rebreather.  The motor generator was wired directly to the
electrical panel and energized using a cut out switch located near the panel.
The air conditioning unit was not an electrical wiring problem since it was
a special unit designed to operate on a 250V DC power supply and was wired
directly into the machine's electrical panel.

     While the electrical hook-up of the life support units had its own
special problems, even more troublesome was the attachment and location of
the life support gear on the mining machines.  The specifications for the
air conditioner and the  rebreather required that neither be more than 12 inches
in height.  The life support gear as delivered met these requirements, however
in mounting these units  it was impossible to keep them out of the operator's
way and clear of the coal rib  and mine roof.

     The following  is a  breakdown of the problems associated with each mining
machine:

Loading Machine  - Joy Model  14BU10-31BH

     The  loading machine is  mounted on rigid tracks and pivots at a point
 somewhat near the  geometric  center of  the machine.  The particular type of
mount for the rebreather and chiller  required that the electrical gauges, i.e.,
 the  wattmeter,  ammeter,  voltmeter, and hourmeter,  be removed from the machine.
The  air conditioning  unit was  mounted  in its place just in front of the
 operator on top of the machine.   The  rebreather was mounted to the rear of
 the operator and over the rear tram motor.  This  placed both the units in
 precarious positions  since  the loader  pivoted in  the manner described.  On a
 rise in the bottom the pivot was such  that  the units could be crushed between
                                       24

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the machine and  the  roof.  This did  happen with  one  unit  as  the operator was
backing the machine  to  the top of a  small rise.  While  the rebreather  case
was destroyed, the rebreather continued to operate and  the operator  had no
difficulty disengaging  himself from  the rebreather.  The  location of the air
conditioning  unit was far enough forward to prevent  the unit from being crushed
in the same manner as was the rebreather.

     The only other  difficulty found with the life support system mounted in
the manner described was a problem of visibility.  The  operator at times had
some difficulty  seeing  over the unit to properly position the machine  to load
a cut of coal.   The  last shuttle car or cleanup  car  was difficult to load
since the operator could not always  see over the top of the  machine  to pick
up the last few  scraps  of coal.

Cutting Machine  - Joy Model 15RU-3A

     The cutting machine contained enough space  to mount the rebreather below
the height of the machine.  The air  conditioning unit was mounted opposite the
operator's normal position on the left deck of the machine.  The rebreather was
mounted just  above the  left hand deck in front of the operator.  Connection
between the two  units was made with  one-inch rigid copper tubing.  The re-
breather location was somewhat less  than ideal since it extended beyond the
width of the  machine.   The operator  had to be careful that the machine remained
clear of the  coal rib at all times.  Visibility  was  no  problem.

Coal Drill -  Gal is Model 460

     All of the  roof drill controls  were set on  the  left side of the roof drill
so it was necessary  to  locate the air conditioner and rebreather as  close as
possible to the  operator's controls.  The operator also had  to be able to set
temporary jack posts to support the  roof while he drilled and inserted the roof
bolts.  The air  conditioning unit was mounted to the rear of the left side of
the operator's deck, with the rebreather mounted above  the air conditioner on
top of the machine.  These mountings proved ideal for the machine's operation
since the overall height of the machine was low  enough  to maintain adequate
clearance between the life support units and the mine roof.

     Connection  between the units was made by using  rigid copper tubing one
inch in diameter with sweat soldered couplings.

Shuttle Car - National  Mine Service Type 48-S18-36AL

     The shuttle car presented a special  problem since space available for
mounting any  additional equipment was extremely difficult to find.   A specially
designed air  conditioning unit plus a motor-generator to provide 115V AC from
the 250 V DC  available  on the machine had to be  installed.   Space available
dictated that the rebreather be mounted atop the shuttle car between  the two
drive wheels  forward of the operator's deck.   The thermionic  air conditioning
unit was more compact than the air conditioners  mounted on the  other  machines;
                                    25

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however, it still presented problems on mounting on the shuttle car.  The only
space available was in the area forward of the operator's deck adjacent to the
electrical panel.  The unit consisted of two components—an electrical power
supply and the cooling unit.  To utilize the space available, the air condi-
tioner had to be mounted on top of the power supply next to the electrical
panel.

     Rigid connections between the chiller and rebreather were not possible
since the various hydraulic lines on the shuttle car made it impossible to
install rigid tubing.  The one inch plastic tubing used for the tethers was
used to connect the two units together.

     The motor-generator was bolted directly to the machine behind the opera-
tor's deck on the side of the conveyor and supplied 115V AC to the 115V AC/24V
AC transformer mounted beside the rebreather.

     These locations had some effect on the visibility of the operator but not
enough to prevent the safe operation of the machine.  The major hazard here
was the possibility of crushing the rebreather between the machine and the
roof.  Clearance at this point averaged around six inches, thus making it
necessary for the operator to exercise extreme care.
                                   26

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                                SECTION  IX

                              MINER TRAINING
                        MINERS' LIFE SUPPORT  SYSTEM

     One miner  assigned to  the project was  used  to adapt  the  chiller  and  re-
breather to  the mining equipment, and to assist  in setting  up the  office
building and in constructing  storage racks  and workbenches, etc.   Only  one
miner was  initially  assigned  to the job as  it was felt  there  would not  be
enough work  to  keep  two men busy.  All preliminary testing  was  done using this
one miner.   The second miner  was assigned to  the project  after  the equipment
had been modified  and just  prior to taking  the equipment  underground.

     After completing the modifications to  the mining equipment to receive  the
chillers and the rebreathers, the remaining life support  systems were received
from MSA Research  Corporation and an additional  life support  suit  to  fit  the
second miner was received from Arrowhead Products Corporation.   The suit  de-
signed to  fit Mr.  Turner fit  the first miner.  The preliminary  draft  of the
Operation  and Training Manual was given to  the miner for  his  review and
education.   Several  sessions  were held in which  the system was  thoroughly
explained  to him and all questions were answered.  The  hazards  of  using com-
pressed oxygen  and the effects of carbon dioxide and carbon monoxide on the
body were  reviewed so that  he was thoroughly  aware of what  to expect from the
system and how  it  could affect his systems.   He  assisted  in servicing the units
and in the modifications to the rebreathers made in the field.  He reviewed the
Operating  and Maintenance Manual and was thoroughly indoctrinated  into  the
operation  and maintenance of  the rebreather.

     On several occasions,  he donned the suit and the life support system was
activated  to familiarize him  with the system—how it felt and how  it operated.
He practiced changing from  the portable uncooled mode to the  fixed  cooled
mode.  This  was done to develop confidence  in the system, mainly the quick  dis-
connect valves  in  the tethers.  When changing tethers, these  valves maintained
the pressure in the  suit.   However, air flow was interrupted  until   the  hookup
was completed.  This created  no problem with either of the miners.   Different
start up procedures  were tried until the approved start up procedure,  as
indicated  in  the training manual, was developed.  See Appendix A.

     Several  tests were conducted with the miner so that he could experience
having the suit sucked down and clinging to him  caused by a leak in the dis-
charge side  of  the blower or  being over inflated caused by a leak on the
suction side  of the  blower.   He was made aware of the action of the oxygen
regulator and to recognize when it was not operating properly.  Every  effort
was made to make him totally  aware of how the system would react under dif-
ferent conditions.   There was no hesitancy at any time on the  part  of  the
miner to don  the suit or to experience these different emergencies. He was

                                     27

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interested in all aspects of the system and was eager to learn.

     During this training period, no effort was made to develop a  highly
technical program and the training period was relatively short.  Every  effort
was made to teach and learn by experience.  Both miners were anxious  to learn
and showed no fear for the system.  They learned rapidly and were  able  to
handle all situations that might develop.

     During this training period, several items of the life support system
were further resolved.  The testing with the leotard stretch garment  was con-
ducted with considerable satisfaction.

     The training and start up procedures were developed utilizing the  first
miner assigned to the project.  He had the advantage of a longer training
period and experiencing some of the pitfalls while developing these procedures.
As a result, he was well-versed in the equipment and its use.  The second
miner was assigned to the project after the development of these procedures
and approximately two weeks before the equipment was to go underground.  He
was trained as described above and had no problems operating the life support
equipment.

     Slight modifications were made to the life support system at  the mine and
the final system as tested in the mine can best be explained pictorially.  The
following figures constitute the Miner's Life Support System that was tested
in the mine.

     Figure 7 - Mine  Personnel Rebreather - modified - shows the rebreather
used in  the mine.  Note the large dial in the center.  This is the pressure
gauge  indicating the  in-suit pressure.  The 24V AC external power  plug  can be
seen at  the right of  the unit in the  "plugged-in" position.

     Figure 8 - Mine  Personnel Chiller-Condenser-A shows the mechanical
chiller-condenser supplied by MSA Research Corporation.  The chiller  can be
seen at  the left of the picture.  Note the connections for the tethers, the
drain  valves, and 24V AC power cord.  The unit on the right is a hermetically-
sealed refrigeration  compressor and the small square unit in the center is the
temperature control.

     Figure 9 -  Mine  Personnel Chiller-Condenser-B shows the thermionic chiller
purchased for use on  the shuttle  car.  The 250V/96V DC power converter  is seen
at the left of  the  picture.  The  unit on  the right is the chiller-condenser.
At the right of the chiller-condenser, you will note the inlet tether connection
and  on the  left,  the  exit  tether  connection.  Visible also are two of the four
minifans used to cool the  unit.

     The rebreather and  the  cooling unit  are the heart of the life support
 system.   They provide the  cool air required for the miners' comfort.  These,
when connected  via  tethers to  the  life support suit, complete the  life  support
 system.

      The following  figures show  the various components that make up the
 life support suits.

                                    28

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10
                                       Mine Personnel Rebreather  (MPRB)



                                                   Figure  7

-------
CO
o
                           Mine Personnel Chiller-Condenser-A  (MPCC-A)

                                             Figure 8

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Mine Personnel Chlller-Condenser-B(MPCC-B)



                  Fiqure 9

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     Figure 10 shows the Mine Personnel Undergarment (MPUG) worn next to  the
skin.  This is a standard cotton knit, long sleeved, long legged set of
underwear.  Its primary purpose is to absorb perspiration, to provide uniform
cooling of the body, and to protect the arms and legs from the chafing of the
gas-tight suit.

     Figure 11 - Shows the front of the gas-tight Mine Personnel Suit (MPS).
Note the storm cuffs at the wrists and on the upper leg.  Note also the
tether connections on the right breast and the helmet mating ring.

     Figure 12 - Mine Personnel Suit (MPS).  Note the across-the-shoulders
zipper which is the entrance to the suit.  This is a standard air-tight zipper
presently used by NASA for their launch support personnel.

     Figure 13 - Shows a front view of the Mine Personnel Stretch Garment
(MPSG).  When compared to the front view of the Mine Personnel Suit, note
the  ability of the stretch garment to confine the Mine Personnel Suit.
Note also the opening for the tethers and the zipper for ease of donning.

     Figure 14 - Mine Personnel Stretch Garment (MPSG).  This is a side view
of the stretch garment.  When compared to the side view of the Mine Personnel
Suit, note how the stretch garment confines the suit.

     Figure 15 - Miner's Life Support System (MLSS).  This is the complete  life
support system showing the miner completely dressed and carrying his helmet.
Note the  use of standard coveralls and the miner's belt and the standard
miner's lamp mounted on the helmet.

     Figure 16 - Miner's Life Support System (MLSS) shows the complete miner's
life support  system in the portable mode.  The rebreather continuously circu-
lates air through the tethers to the miner and back to the rebreather,
providing all  his breathing requirements.  No cooling is provided in this mode.

     Figure 17 - Miner's Life Support System (MLSS).  This shows the position
of the  various components  in the rebreather case when in the portable mode.

     Figure 18 - Miner's Life Support System (MLSS).  This shows the miner
with the  life support system in the portable mode ready to enter the mine.
Note on the helmet  just  behind the visor a little black dot.  This is where
the  communications  cord  passed through the helmet.

     After reviewing  these figures, note that standard garments were used
wherever possible;  that  is,  standard  underwear, standard stretch garment, and
 standard coveralls  were  used.  The assembled life support system worn by  the
miner  looks  like  it belongs  in the mine  and should be totally accepted by the
miners.  This is  the  system  that was  tested in the mine and proved
 satisfactory.

      The Operating  and  Training Manual for the life support systems and
 the Operating and Maintenance  Manual  may be found in Appendices A, B, C,  and
                                     32

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OJ
u>
                                      Mine Personnel  Undergarment (MPUG)


                                                   Figure 10

-------
Mine Personnel Suit (MRS)
        figure 11
             34

-------

Mine Personnel Suit - "PS
       Figure 12
              35

-------
Mine Personnel Stretch Garment (MPSG)



             Figure 13
                  36

-------

Mine Personnel Gtretch Garment (MPSG)



              Figure 14
                  37

-------
Miner's Life Support System (MLSS)
             Fioure 15
                 38

-------
Miner's Life Support System (MLSS)
             Figure 16
                  39

-------
Miner's Life Support System (MLSS)
             Figure 17
                40

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                               —B
Miner's Life Support System (MLSS)
      Ready to Enter the Mine
             Figure 18
                 41

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                                 SECTION X

                                 TEST SITE

     Island Creek Coal Company's Pond Fork Mine, located approximately 14 miles
east of Madison, West Virginia, along West Virginia Route 85, near the small
town of Kohlsatt, was chosen as a suitable location for the project tests.
The mine began operation in April, 1970, with an expected annual production
of 950,000 tons per year.  Two separate seams of coal are being actively mined.
They are known as the Dorothy Seam and the Number Five Block Seam.  Both seams
are being extracted through drift openings by conventional room and pillar
methods of mining.  They are above drainage, with the Five Block Seam located
above the Dorothy Seam.  All coal is removed from the face areas by belt
conveyors to the outside where it is stored in concrete silos before being
transported and processed through the preparation plant located on the valley
floor.

     This site was chosen for several reasons.  Preliminary investigations
determined that this mine had a better than even chance for the production
of acid mine water drainage.  It was nongassy and had an average working height
at the mine faces of 48 to 60 inches.  The Pond Fork mine was one of Island
Creek's newer operations and met all of the desired conditions for the project.

     The Phase II office was built on the Dorothy level at the latter extent
of the outcrop shown on Figure 19.  This location was the closest to the main
mine portal that the building could be placed.  Several weeks of grading and
slope stabilization had to be done before a reasonably safe foundation for the
office could be constructed.  Several drainage ditches and drain pipes had
to be installed before constructing the building.  After the site had been
stabilized, the building was constructed by a local contractor.

     Since some testing of the mining equipment was required at the office
building, a power supply to serve the 500 KVA underground mine power center
had to be installed along with the lighting and heating transformer to supply
power to the Phase II office.  Approximately 900 feet of right of way had to
be cleared and a number of poles installed to run the high voltage lines up
the hill from the coal preparation plant in the valley to the project office.
Water and sewage treatment facilities were purchased and/or installed but
never placed into operation due  to pending labor problems at the mine.
As a result, no facilities were  installed for showering, washing, or otherwise.
However, all sewers,  floor  drains and ventilation lines were installed.

     The particular  test area  in the Dorothy seam was chosen because it had
the required seam height and was  readily accessible to the surface facilities.
Several  possible  test sites were reviewed and the area selected for the test
face was  located  approximately 2500  feet from the main portal in the First

                                      42

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-^„  SSoDDDDO
             Daaaaao oa a oa oca a
          aoaoDoa oaaa ao DO
                               '

                               Location of Test Section
                                   in Pond Fork Mine
                                       FIGURE 19
                           43

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West Mains area of the mine.  There was another active working section  in  the
area in by the test face.  This required that the test section be placed on
a completely separate split of air, i.e., the air supplied to the test  section
would be directed toward the fan with no possibility of reaching any other
working faces in by the test areas.  See Figure 20 for the ventilation  plan.

     The necessary ventilation controls to direct the airflow were constructed
during the miner's annual vacation period so as not to interrupt normal
operation of the mine.  Visits to the area before the airflow change indicated
that the area was in a relatively neutral air split and that conditions were
ideal for the test section.  The area was clear of obstructions, had a  firm
bottom, good top, and was reasonably dry.  These conditions changed after  the
air was directed across the area.  The section's proximity to the outside
meant that there would be considerable sweating of the top as warm moist air
was cooled as it passed over the area.  The resulting moisture caused the
top to slake considerably causing roof failure between the roof bolts thus
loosening the roof support in the area.  As a result of this, considerable
time was required to clean up the area and make it safe again before any
mining operations could begin.

     This clean up work was delayed as the mining equipment purchased for  the
project was required to do the job and permission had not been received from
the U. S. Bureau of Mines to take this nonpermissible equipment underground.
Immediately following the receipt of the permission to move the machinery
underground, all equipment was moved to the face area using the local mine
personnel.  This was done on a weekend so as not to interrupt the normal
mining operation.

     Following the movement of the equipment underground, several days  were
required to repair the damage to the equipment caused when dragging it  to
the work face.  The loading machine cable had to be detached from the machine
and spliced, and the cable guard had to be replaced.  The operator's seat
bracket was twisted and  the cable chain guard was torn from the machine.   The
500 KVA power center was hooked up in the wrong heading and had to be moved
and reinstalled in another heading.  The drive chain on the cable takeup reel
on  the shuttle car was broken and had to be spliced.  The cutting machine  did
not have a low voltage cable couplings attached and it was necessary to splice
a coupler to the machine cable before it could be used at the test face.
This same condition applied to the roof bolter.  All of these repairs had  to
be  completed before any  type of face operations could begin.

     Following the equipment repair the cleaning up operation began.  Using
the loader and shuttle car, project personnel cleaned approximately 480 feet
across  the face area  for a  length of four breaks for two headings.  The
material was dumped out  by  the face in the old works since there was consider-
 able rock  and  no way  of  loading  it on the belt conveyor.  Cleaning operations
 included  the final  shoveling of  all ribs to remove coal or fine dust.
                                     44

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              paaaaoc
                     p o C
                 D a o D c
                 U n^^o c
               a
               a oa
             a p D
        __ C3D C7 ahDt3
    o a a D n n
annna DDDDDDDDQ
          Test Section
        Ventilation Plan
           FIGURE 20
45

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Following the cleaning the entire area was machine- and hand rock-dusted,
requiring approximately 15 tons of rock dust.

     While initial roof supports were installed in the area before any
personnel were allowed to work, the slaking of the roof had loosened many
of these roof bolts and these had to be replaced.  In addition nearly 200
timbers were set in the area to bring the section up to the standards
required by mine law.  Roof bolts were spotted as needed and any extensive
bolting was done to the standard five foot centers as required in the mine
permit.  Timbers were set along both sides of the roadway narrowing them to
16 feet wherever the untimbered areas exceeded 20 feet in width.

     After securing the roof, the ventilation was changed to bring the entire
airflow across the working faces rather than letting a portion pass through
the first heading out by the working face.  Check curtains were placed at
both ends of the section and fly curtains were installed as needed to air lock
the air passing across the face and to prevent the short circuiting of the
air.  Airflow across the face was averaging more than 15,000 CFM at the intake
and 12,000 CFM in the returns.

     In order to maintain haulage to the belt conveyor from the face area, a
track crossing for the shuttle car was built using 3 inch x 6 inch x 14 foot
planks installed perpendicular and parallel to the mine track.  The area under
the track was shoveled to the bottom rock base.  Planks were laid perpendic-
ular to the rails for the entire width of the mine roadway and ballasted.
Two planks were placed underneath each mine rail and spiked to the rail using
the six inch spikes available at the mine.  Additional planks were laid
parallel to the track both between the rails and outside to give a smooth
crossing for the shuttle car.  These planks were nailed to the planks under-
neath to complete the track crossing.

     The limited height of the area at the track crossing required that the
existing trolley wire be countersunk and guarded to provide safe passage of
the mining equipment under the wire.  This was accomplished by drilling 23
one foot holes into the roof the entire width of the haulway.  Following the
drilling, two 1 inch x 8 inch x 14 foot planks were installed on each side
of the holes using standard 30 inch roof bolts and timbers were set between
the roof bolts.  The holes were then charged and fired in a ten shot, ten
shot, three shot sequence.  The resulting roof break allowed the trolley
wire to  be lifted above the surrounding roof and out of the way.

     Following the completion of the track crossing and trolley wire counter-
sinking, the loader  and shuttle car were able to cross the tracks and clean
the haulway to the belt conveyor.  This area also required additional roof
bolting  and timbering.  A side dumping loading station at the belt conveyor
loading  point was  installed by project personnel during a shift when the belt
conveyor was idle  to complete the  section set- up.  All of the foregoing work
was required before  any of the Phase II testing could begin.  Considerable time
was spent in preparing the section, resulting in additional delays and
shortening the test  period of the  equipment.  Figure 21 is the general
arrangement of the completed test  face.


                                    46

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        STOPPING
         RADIO  ANTENNA

          TRACK
        BELT CONVEYOR
        .4160 VAC  CABLE
        500KVA TRANSFORMER
             I90KW  RECTIFIER
              TEST FACE
          EXPLOSIVES
              CHECK  CURTAIN
             Test  Section
         General  Arrangement
              FIGURE 21
47

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                                SECTION XI

                              COMMUNICATIONS

     The "leaky cable" communications system from Motorola Communications
System, Incorporated, recommended in the Phase I report was purchased for use
on the project (see Appendix G).  This included a VHP base station or trans-
mitter, four portable high frequency FM transceivers, one remote console type
transceiver, and a remote monitoring station.  The antenna cable was purchased
directly from the manufacturer.  These units were installed and comprise the
basic communications system.

     Radioear Corporation supplied the hearing aids that were used by the
miner to sense the in-mine noise.

     The portable transceivers contained a push-to-talk switch to press when-
ever a message was being sent.  Since the miner was inside the helmet, some
other means of operating the transceiver had to be provided.  A radio receiver
and microphone had to be mounted inside the helmet and a means provided to
automatically activate the microphone whenever a message was sent.  A voice-
operated relay (VOX) was supplied by Motorola to do this.  This unit clamped
onto the transceiver and plugged into a receiver and microphone located in a
standard hard hat.  The microphone and receiver had to be remounted in the
helmet supplied by Arrowhead.

     The hearing aid supplied by Radioear was wired to a standard hearing aid
ear plug.  This setup could not be used in the helmet as it would be difficult
to don the helmet and the pressure from the ear cup would be uncomfortable
over an extended period.  Another type of receiver was required.

     The helmet supplied by Arrowhead was equipped with foam ear cups with a
molded recess for a standard telephone receiver.  To use any other receiver
would require a special mold for the ear cups and increase the cost of the
helmet.  Both Motorola and Radioear agreed that their equipment would operate
satisfactorily using the standard telephone receiver.  The Motorola service
center in Pittsburgh was contacted to make the necessary changes to adapt both
the hearing aid and radio to the helmet.

     One of the first problems  faced was how and where would the wires pass
through the suit  to connect  the radio to the ear receiver.  A receptacle at
the left breast area  of the  suit was tried.  The wires ran inside the suit to
a plug  at the  neck  ring.  To  complete the in-suit connection, a plug in the
 helmet would be plugged into the plug at the neck ring, after the helmet was
 put on and  before the neck  ring was  closed.  A mating plug on the radio would
 plug  into the  receptacle  on the suit to complete the system.  The receptacle


                                      48

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on the suit created a pressure point that was very annoying and the plugs at
the neck ring were extremely difficult to mate.  As a result, alternate
systems were tried.

     The most acceptable system proved to be a connection located behind the
right ear on the helmet.  Arrowhead developed a special fitting that permitted
the wires to pass directly through the helmet without the need of plugs.
Silicone rubber was used to make an air-tight seal at this point.  Two sets of
wires exited the helmet at this point.  One set was for the radio and micro-
phone and the other for the hearing aid.  Suitable mating plugs were provided
to complete the system.

     Inside the helmet, the hearing aid was wired to the receiver in the
right ear and the radio was wired to the receiver in the left ear.  Figure 22
is the wiring diagram for the helmet.  Two different types of microphones
were tried.  A boom microphone was located on the helmet ring in front of the
mouth in two helmets and a bone conducting microphone was located in the helmet
support straps at the back of the head in the other two helmets.  This enabled
the miner to hear mine noise through the hearing aid in the right ear and
radio messages in the left ear-  To transmit all he had to do was to begin
talking and the voice operated unit would close and the message would be
transmitted.  All helmets were wired in this manner.

Installation

     The outside communications components, the remote console transceiver and
base station, were located on the Dorothy Seam level of the Pond Fork mine.
The base station was located at the mouth of the main mine portal  and the
remote station was placed in the mine shops.  These units were connected by
570 feet of two conductor mine telephone cable.  The remote transceiver was
placed in the mine shops because there would always be someone present to
receive messages.  Telephone cable was installed from the shop to the Phase II
office for possible relocation of the remote transceiver.  The connection was
never made since all needed contacts were made through the shop.

     The base station or transmitter was mounted on the rock dust storage
silo located at the mine mouth.  440V AC power was supplied to the unit from
an existing transformer in the area.  A small  440V AC/115V AC transformer was
installed adjacent to the transmitter to reduce the power to 115V  AC for the
transmitter.  Power was maintained to the base station at all  times in order
to keep"the unit at normal operating temperatures and moisture free.   From
the base station a length of co-axial cable ran to the balun or transition
unit for connecting the co-axial  cable to the  underground antenna  to provide
a balanced signal, and mated to the antenna cable in the mine.

     To test the system the antenna cable was  placed in the track  heading
because it was felt that communications would  be better maintained in  this
manner.  Traffic through the area was more frequent and the cable  could be
better observed for easy troubleshooting and maintenance.
                                     49

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3
     BARE  3RD.
     WHITE 	
RECEIVERS
WESTERN ELECTRIC
MODEL NO. HC 3
      RED
      BLACK
          PLUG
     WIRING  DETAIL
       RADIO PLUG
       KING ELECTRONIC €0. INC.
       MALE PLUG NO. K-1833-8
      (SEE WIRING  DETAIL ABOVE)
                                                             SETCOM BONE
                                                             CONDUCTANCE  MICROPHONE
                                                             (ALTERNATE-USED
                                                              IN 2 HELMETS)
                                                                                          HEARING AID
                                                                     BARE GRD  8
                                                                      TAN
                                                                                              RED  8
                                                                                              BARE GRD.
RADIO  RECEIVER
   WHITE  a
 BARE GRD
                                                                        HELMET
                                                                        LOCKING
                                                                        RING
                                                                                               HELMET
                                                                                               SHELL
                                                           PLUG   VIEW
                                            FIGURE 22
                             COMMUNICATIONS  WIRING  DIAGRAM
                             MINERS LIFE  SUPPORT  HELMET
                                                         RADIO MICROPHONE
                                                         PACIFIC
                                                         PLANTRONICS.INC.
                                                         MODEL NO MS 50
                                                         (USED IN 2 HELMETS0

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     The recommendations at the time the cable was installed were that the
antenna had to be placed a minimum of eight inches from the mine roof and coal
rib.  This was recommended in order that the cable could give the proper
operating characteristics.  The cable was hung using 21 inch heavy duty
Panduit plastic tie straps either nailed to a mine timber or attached to an
existing roof bolt.  Care was taken for the first few hundred feet to keep
the cable at the proper spacing and away from any hazards.  The cable was then
allowed to contact both the roof and the rib at several different points.
This supposedly would destroy the radiating ability of the cable.  Subsequent
testing proved that touching the roof or rib had no effect on the cable's
performance.

     The antenna was able to pick up signals from the transceivers through the
limestone block stoppings running parallel to the entire length of the antenna.
For this reason, the antenna position was moved from the track heading to the
first section heading and hung for a distance of approximately 80 feet from
the first working face on the test section.  The antenna was then taken to the
first heading out by the face of the test section and hung for the length of
the section for a distance of about 350 feet.

     The height limitations of the equipment and roof made it virtually
impossible to keep the antenna at the specified minimum distance of eight
inches from the roof and ribs.  The eight inches would not provide sufficient
clearance to keep the cable from being snagged by the equipment.  Since the
earlier experience had shown that the proximity of the cable to the roof did
not hinder communications, the cable, hanging across the face, was tied as
close to the roof as was possible.  The resulting performance further con-
firmed that this method of hanging the cable did not hinder communications.

     Shortly after installing the antenna, a roof fall buried the antenna
for approximately 80 feet.  A rock fall of this type was thought to interrupt
communications beyond this point.  There appeared to be no loss in signal
strength and communications were maintainable beyond this point throughout
the project with no difficulty.

     In hanging the antenna cable, it was necessary to splice it on three
different occasions.  One splice was for the connection between the co-axial
cable and the underground antenna and the other two along the length of the
cable.  The splicing procedure as outlined by the cable manufacturer was
deviated from in actual practice.  The procedure was lengthy and difficult
to make a'nd the materials used were difficult to work with.   Cutting the
plastic spacer for keeping the dielectric spacing constant was particularly
difficult.  The plastic insulation was difficult to cut and molding the spacer
to hold the wire conductors required considerable time.   To complete the
splicing of the wires in the cable, a standard shrink type vulcanized splice
commonly used in the mine was used to cover the splice.   This gave the cable
the strength and flexibility needed for good performance and provided the
necessary moisture proofing.
                                      51

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     The actual testing of the communications at the test face was very
encouraging.  No particular precautions had been taken during the installation
of the antenna and little maintenance was required for any of the equipment
once the installation was completed.  Communications with the surface were
immediate, time saving, and made with little difficulty.   Portable to portable
communications proved excellent for line of sight talk.   The only difficulties
arising when the distance between them was great enough to involve some roof
and bottom rolls.  Communications between portables was good in the section
area for the length of 300 feet or so, but was greatly reduced whenever two
lines of mine pillars were between them.  Under these conditions, it was
necessary to relay messages to the mine shop and back.  Overall, the communica-
tions system installed proved to be invaluable when considering the time saved
and ease with which the units allowed communication with the surface.

     Some difficulty was experienced when trying to talk to the man while the
machinery was running.  The machinery noise made it difficult to hear incoming
messages and on many occasions the miner did not realize he was being called
on the radio until the machine was shut down.  Some means of alerting the man
to incoming messages is required.

     The voice-operated relay system used to activate the microphone for
transmission proved troublesome.  In many cases, the first word or two of the
conversation was lost due to the time delay required for the relay to operate.
In order to satisfactorily use this system, it was necessary to clear your
throat or activate the relay with some other meaningless noise.  The relay also
appeared to chatter and operate for no apparent reason when no messages were
being sent.  This was annoying and as a result the push-to-talk mode was used
for most of the transmissions.  This proved quite satisfactory and all future
communications should be conducted in this manner.

     The boom microphone presented some problem in that the location of the
microphone in respect to the mouth appeared to be critical, causing the message
to come and go as the man talked.  It was difficult to reposition the micro-
phone for best communications as the man could move his head inside the helmet.
He would have to have his helmet on in the exact same position each time he
wanted to talk.  The bone conducting microphone did not have any of the
problems associated with the boom microphone.  Satisfactory communications
were obtained at all times.  The position of the microphone on the head and
the amount of hair did not appear to affect its ability to perform.  The bone
microphone should be used for any future communications of this type.

     The hearing aid enabled the man to hear the in-mine noises; however, it
was difficult to sense the direction of the origin of the noise.  Not only did
the hearing aid amplify the in-mine noise, it also amplified the noise of the
mining equipment.  As a result,  the volume control of the hearing aid was
turned down, reducing the man's  ability to hear other noises.  No concentrated
effort was made to evaluate this problem due to the limited testing performed
and the precedence of other problems.  A means must be developed to selectively
dampen the  background machinery  noise while amplifying the other noises.
                                      52

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RECOMMENDATIONS

     Additional work is required to evaluate the performance of the radio and
     hearing aid and a means developed to receive both the radio and hearing
     aid in both ears.

     Directional hearing using the hearing aid is required to enable the
     sensing of the direction of noises.

     The voice operated relay system should be replaced with a push-to-talk
     button.

     The antenna cable should be of a more flexible design allowing more
     stretch and bend.  Cold weather installation particularly aggravates this
     situation.

     Antenna cable should be of a type not requiring any minimum distances to
     be maintained from any underground structure, other than for safety
     reasons.

     A repeater type system would allow personnel to maintain direct communica-
     tions with one another without relaying through the surface equipment.

     The cable should be rugged enough to withstand any crushing coming from
     either rock falls or from equipment running over it.

     The cable hangers used for installation should allow the cable to bend or
     flex whenever the cable is bumped.

     The spacers used in splicing the cables should be pre-cut for the proper
     dielectric spacing to provide more ease in installation.

     Whenever the cable is installed at a working face, it should be hung
     across the first line of breaks out by the loading point.   This method
     will give full coverage of the face areas and minimize installation
     problems.
                                     53

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                               SECTION XII

                            IN-MINE TESTING
                       MINER'S LIFE SUPPORT SYSTEM

     The many delays in the project limited the in-mine testing to a period
of six weeks, whereas the original  schedule called for six months of in-mine
testing.  The installation of the communications system was completed before
establishing the in-mine test face and was used extensively while the test
face was being readied for the test program.  Once the test face had been
established and met all the mining safety regulations, the testing of the life
support system began.

     The test face was located inside the adjacent mine approximately twenty
five hundred feet from the main portal.  Transportation to the test face was
via the mine scooter.  Figure 23 shows the two miners with their life support
systems on board the mine scooter,  ready to enter the mine.  All personnel
and equipment were taken into the mine in this manner.

     There were no provisions in the project to provide a transport vehicle
capable of transporting a completely suited man to the test face.  The men
therefore had to carry their helmets and rebreathers into the mine.  Once
reaching the test face, the rebreathers were mounted on the mining equipment,
the tethers were connected to the suit and rebreathers, the helmet was donned
and the system put into operation.   This gave time to make the hookup and
overcome any delays that might occur in the mine.  On at least one occasion,
this did present some problems.  The heat built up in the gas-tight life
support suit to the point where tests had to be cancelled because the miner
had become overheated and developed a chill when the air circulation system
was placed in operation.  The delay caused by waiting for transportation to
get into the mine and an additional delay in the mine due to mining equipment
problems created this situation.

     The second miner had been assigned to the project just prior to taking
the equipment underground to develop the test section.  Time was taken to
train and educate him in the use of the life support system.  On two or three
occasions he put on the suit and was instructed on how to place the system in
operation so that he understood the system and had no fear of it.  His training
was held to a minimum to determine the reaction of the man to minimum training
and the confidence he might have in the system.

     In order to familiarize each man with operating the mining equipment while
using the life support system, each man was taken into the mine separately.
All other project personnel observed the tests.  The No. 2 miner was the
second miner assigned  to the job, but  the first one to test his life support
equipment at the test  face.  The first miner had previously demonstrated his

                                      54

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Miners Ready to Enter the Mine



           Figure 23

-------
capabilities using the life support system earlier in the project for a group
of visitors.

     The second miner suited up in the office and was driven in a truck to the
mine scooter and taken to the test face.  Here is was necessary to move some
mining equipment around to position the first piece of equipment to be tested,
which was the coal cutter.  The helmet was placed on the deck of the cutter
while tramming and when passing through one of the curtain barriers, the helmet
was brushed off the cutter and underneath the wheel.  The visor popped out and
the helmet was crushed to the point where the internal ear cups touched each
other.  On retrieving the helmet, it appeared to return to its normal  shape
and there appeared to be no structural failures.  The visor was replaced and
the helmet was put on to determine if there was any misalignment of the helmet
ring.  The helmet mated perfectly with the ring and the life support system was
put into service to determine if the system remained tight.   All checks indi-
cated that the system was tight.

     Since the system appeared to be air-tight and only one helmet had been
taken into the mine, the test program was continued.  The miner proceeded to
make a cut of coal.  These activities were documented on film using a  Super
8mm movie camera and a 35mm camera.  He had no difficulty in operating the
cutter.  However, the neck collar seemed to bother him as he tried to  look to
the rear.  This was his only problem; however, he was able to compensate for
it.  There appeared to be no problem with the location of the miners'  lamp on
the helmet and visibility through the visor appeared to be good.

     One problem developed as a result of the accident with  the helmet.  The
internal air distribution system in the helmet had been ruptured and only half
the visor stayed free of fog.  The part that did fog up was  not unbearable
and the man was able to continue operating his equipment for the duration of
the test program.  He did comment that the chiller was keeping him too cold,
and that there had to be a better means of controlling the temperature of the
air in the system.

     The following day, the other miner was brought into the mine to operate
the roof bolter.  He had previously operated this machine while using  the life
support system and had no problem.  This was again the case.  All activities
were again documented on film.

     In the following test, the No. 2 miner in the life support system opera-
ting the coal drill drilled the face that had previously been cut.  The coal
drill was somewhat unfamiliar to this miner, and the operation was rough.
However, he had no problems in maneuvering the machine or in observing what he
was doing.  Drilling time did not appear to take any longer than a normal drill
sequence.  Here again, these activities were documented on film.

     Following the drilling operation, the No. 1 miner with the life support
system in the portable mode proceeded to charge and shoot the face.  The
                                      56

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rebreather was placed in a standard "Flexible Flyer" wagon purchased for
small hauling jobs in the mine and to demonstrate a means of handling the re-
breather in the portable mode.  With this he was able to pull  the rebreather
behind him and let it sit away from the area where he was working.   He had no
problems in planting the charges or making connections.   Care, however, was
exercised to keep his shooting cable from becoming tangled in  order to facili-
tate the pulling of the wagon while laying the cable prior to  firing the shot.

     The following day, both miners wearing life support suits entered the mine
and proceeded to load the coal onto the belt conveyor.  The No.  2 miner's
regular job was that of loader operator and the No. 1  miner's  regular job was
shuttle car operator and roof bolter.  They mounted their life support systems
on their respective pieces of mining equipment and proceeded to load coal.
There appeared to be no problem in this operation.  The  loader had complete
control of his equipment, complete visibility, and was hampered in no way.   The
dust created by the loading operation appeared to be repelled  by the visor on
the helmet so as not to cause a visibility problem.

     The shuttle car operator was able to observe the loading  of the shuttle
car and change his position without difficulty.  He had  no problems in unload-
ing the machine onto the belt conveyor at the other end.  These sequences of
operation were also documented on film.

     Figure 24 shows the miner kneeling beside the loader.  Note the location
of the life support system on the loading machine.  Figure 25  shows the miner
operating the loader.

     Figure 26 shows the No. 1 miner tramming the shuttle car  towards the
belt heading.  Note the location of the rebreather on the shuttle car.   Figure
27 shows the shuttle car operator in the alternate position.   Note the load of
coal on the conveyor beside his helmet.

     Figure 28 shows the roof drill in operation while Figure  29 shows the
maneuvering of the machine.

     Figure 30 shows the miner operating the coal  drill.  In no  way does  it
hamper his visibility or his ability to operate the machine.

     During the use of the roof bolter (pin machine) a hydraulic fitting  on the
underside of the machine was ruptured.  In order to demonstrate  the ability
of a suited man to make equipment repairs, it was decided that one  of the men
would repair the machine while in the life support suit.  The  No.  ] miner
trammed the roof bolter to an appropriate area for repairs.  The procedure  to
be used to make the repair was reviewed with the test engineers  and the miner
proceeded to replace the broken fitting.  The total time required to make the
repair was approximately 12 minutes.
                                      57

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en
00
                                      Miner and  the  Loadinn Machine


                                                 Figure 24

-------
en
                                 Miner  Operating  the  Loading  Machine



                                              Figure  25

-------
Miner Tramming the Shuttle Car



          Figure 26

-------
Miner Loading the Shuttle Car



          Figure 27

-------
ro
                                          Miner Operating Roof Bolter



                                                     Figure 28

-------
OJ
                                      Minor Tranminq the Hoof Boltar



                                                 Figure 29

-------
Miner Operating the Coal Drill



            Figure 30

-------
     During this operation, the miner was required to bend down and look up
underneath the machine.  The machine had previously been blocked up to give
him working room.  Whenever he looked under the machine, the helmet stayed
firmly on his head and did not slip one way or the other.  It presented no
problem at all.  The standard miners' helmet would have fallen to the ground.
This further demonstrated the ability of the simple stretch garment to control
the helmet-rise problem and that the helmet presented no problem as far as
maneuverability nor did it hinder the ability to perform in-mine tasks.

     To further demonstrate the capabilities of a suited miner to perform in-
mine work, two timbers were knocked down and reset.  There were no problems in
setting the timber, picking up the wedges, placing the wedges and driving them
home.  The life support system was attached to and powered by an adjoining
piece of mining equipment.  The man was able to stay cool and still had ample
room to perform this work.  These activities were recorded on film.

     In order to demonstrate additional freedom of the system, the miner,
with the life support system still attached to the machine, dismounted, picked
up a shovel and proceeded to clean the ribs or shovel  coal from the side of
the mine into the center for pick up by the loader.  He performed this work
without any problems and the tethers did not interfere with his actions.   He
remained comfortable and did not break a sweat while doing this work.

     The many project delays reduced the in-mine testing period to six weeks,
making it impossible to carry out the program of testing, modifying,  and re-
testing the equipment in order to develop a reliable system.   The delays in
getting to the test face caused by long waiting periods for transportation to
get in and out of the mine consumed considerable time, limiting in many cases
the time in the mine to three hours or less.

     In addition, several tests had to be terminated due to mechanical  failures
in the chiller and rebreather systems.  The initial test was carried  out only
because the helmet that had been crushed was able to be kept in service.   On
at least two occasions, vibrations caused leaks to develop in the mechanical
refrigeration systems causing the loss of refrigerant and resultant cooling.
At least two fittings were accidently torn off of the chiller unit, putting
them out of service.  The fragile construction and the protrusion of  the
fittings were the basic cause of these failures.   A complete redesign  of  the
chillers is required to overcome these problems before additional  testing is
undertaken.

     On another occasion, the oxygen sensing line protruding  from the  tether
and connected to the rebreather was broken off.  It was accidental, but it
did pinpoint how fragile the system was and that a more rugged and  reliable
system of controlling the oxygen injection into the system must be  developed.

     The oxygen sensors in each of the rebreathers failed.  An investigation
into the cause revealed that the sensor, under normal  conditions,  had  a one
                                     65

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year life, which had been exceeded.  It was therefore necessary to purchase
new oxygen sensors before testing in the mine.  The location of the oxygen
indicator on the rebreather presented a problem.  On one piece of equipment,
when passing through the mine curtains, there was enough friction to turn the
oxygen monitor off or on, depending on which direction you were traveling.
This created some problems and a method must be developed to control this.

     Towards the end of the project, there was no emergency battery power in
the rebreathers.  Even though the lights on the battery charger indicated the
battery was fully charged, they weren't.  The shelf life of these batteries
had apparently been exceeded and there were no replacement units on hand.   As
a result, tests in the portable mode could not be performed.   All  tests  had to
be conducted while the rebreather was plugged into the power source on the
nearest piece of mining equipment.  The battery system should be redesigned
to facilitate the easy changing of batteries.  In addition, a battery charger
in the service building or in the mine could serve as a source of recharged
batteries for extended emergencies.

     Toward the end of the project, some of the blowers appeared to be labor-
ing and not performing the way they did when they were new.  Part of this could
be directly related to the battery failures.  However, it also appeared  to
happen when operating on the 24V external  power supply.  This problem was not
resolved and should be investigated prior to considering the continued use of
these blowers.

     The locations of the rebreather and chiller on the mining equipment
appeared to be satisfactory in most cases.  However, the rebreather on the
loader was pinched against the mine roof.   The case was knocked out of shape;
however, the internal mechanism of the rebreather continued to function.
Every effort should be made to make the rebreather smaller, more compact,
lighter in weight, and easier to carry.

     The initial tether length of 9 feet was chosen as this was the standard
length in which the hoses were made.  This length was satisfactory for most
jobs in the mine.  However, there was not enough time to determine the optimum
length of tether required for each operation in the mine.  An expandable tether
system expanding from the compressed state of six feet in length to an expanded
length of 18 feet would be most desirable.  Such hoses are on the market and
should be investigated for this use.

     In summarizing the in-mine testing program, the miners were able to
operate their mining equipment and perform various in-mine tasks while wearing
the life support system.  The malfunctions experienced with the mechanical end
of the system indicate a definite need for further testing and redesign  of the
life support equipment in order to develop a reliable and foolproof system.
                                       66

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RECOMMENDATIONS

     The following should be taken into consideration when redesigning the life
support system.

Rebreather

     All electrical components should meet permissibility requirements.

     Batteries should be installed in such a manner as to be easily replaced.

     The recharge rate of the batteries is too long—16 minutes recharging for
     each minute of use.  Alternate methods of recharging the batteries  should
     be considered, including the use of a rapid pulse recharger.

     The in-mine storage of charged batteries and the replacement  of these
     batteries in the mine should be considered.

     The entire unit needs to be reoriented to make it smaller and more
     compact.

     The case should be constructed of nonconductive material.

     All materials of construction should be reviewed to conserve  weight.

     A review of the need for the DP cell should be made.   Its  function  does
     not appear to justify the additional weight and space.

     The C0? canister should be redesigned to 6e more compact,  lighter,  less
     subject to corrosion problems, and easier to service.   Prepackaged  units
     already available on the market should be considered  for this use.

     The tether connections would be more convenient if they were  on  each  side
     of the carrying handle on the case.   This would eliminate  dragging  the
     tethers with the possibility of catching them on something.

     A more reliable means of oxygen control  is required.

     All units should be readily replaced.   The need for modifying purchased
     subassemblies should be eliminated.

     The blower selection should be reviewed for serviceability.

     Alternate life support schemes should  be reviewed  such  as  a small portable
     unit to enter the mine in the portable mode,  and then connectable to the
     main life support unit mounted on the  machinery.   The portable unit would
     also serve as an emergency backup unit.
                                      67

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Chiller

     The present mechanical chiller should be redesigned to eliminate vibration
     failures and to make it more compact.

     All fittings should be located so as to be protected against accidents  that
     would break them off.  The construction of the unit should be reviewed  to
     strengthen these fittings.

     A better temperature control is required.  The main complaint was that  of
     being too cold.

     The overall size of the unit needs to be reduced to facilitate mounting on
     the mining equipment.

     The use of a hydraulic turbine drive for the unit should be investigated.

     The use of a power takeoff from the hydraulic pump drive should be
     investigated.

     The mining equipment manufacturers should be contacted to review these
     possibilities and assist in mounting the chiller on the machine.

     Additional testing should be conducted with the thermionic chiller to
     evaluate its overall capabilities.  Due to limited in-mine testing this
     unit was not adequately tested.

     A compressed gas operated chiller should be developed for short term
     uses such as on the porta-bus and boss cars where available power may be
     limited.

     Other means of cooling should be investigated.


Life Support Suit

     Review the design of the helmet and neck area in an effort to reduce the
     weight and bulk of the unit and to facilitate ease of head movement.

     Review the tailoring of the stretch garments to facilitate donning and
     comfort.  Those tested tended to be too confining and created some
     pressure points.  A larger suit of the same design may be required.

     The internal air ducts created pressure points in several places, partic-
     ularly the neck area.  Location and construction of these ducts should  be
     revi ewed.

     A quicker means of removing the visor under emergency conditions is
     required.

     The air  flow noise  in the helmet  needs to be reduced and air distribution
     across the visor needs to be improved.  The left side of the visor had  a
     tendency to fog while the right side remained clear.
                                      68

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Emergency Rebreather

     Alternate emergency rebreathers should be investigated  to reduce  the
     weight and minimize operator interference.  The operator continually
     was adjusting the unit to keep it out of the way.

     Future emergency rebreathers of the type tested should  be packaged  with
     longer neck straps.  The present neck strap is not long enough to go
     over the man's helmet.  This caused a delay in activating the unit  and
     the total weight of the unit was supported by the  bite  mouthpiece while
     he tried to slip the strap around his neck.
                                      69

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                               SECTION XIII

                              WATER ANALYSIS

     A water sampling program was undertaken on the Price Branch of Pond Fork
Creek in order to develop background information by characterizing the water
quality in the area.  The demonstration mine site is located near the head
waters of Price Branch and any water drainage from the demonstration mine
could affect the water quality in Price Branch.  This background information
will play an important part in evaluating the effects of the demonstration
mine water discharge.

     Strip miners have been active in the Price Branch watershed.  The outcrop
of the Dorothy seam has been auger mined in its entirety except for the section
set aside for the demonstration mine portal.  The spoil has been pushed over
the side of the mountain and could adversely affect the quality of the drainage
water in the area.  The Number Five Block coal  seam approximately 150 feet
higher up the mountain than the Dorothy seam has also been auger mined and its
spoil pushed down the side of the mountain.  Drainage from the Number Five
Block area constitutes part of the head waters of Price Branch.

     Midway down the valley between the demonstration mine site and Pond Fork
is the sludge lagoon serving the preparation plant for Pond Fork Mine.   Price
Branch water coming down the valley flows underneath the sludge lagoon through a
culvert pipe.  Local sand, gravel, and clay was used to backfill  around the
culvert pipe to form the bottom of the sludge lagoon and to act as a filter
for lagoon water percolating into the culvert pipe.  Coal  mine refuse was
used to construct the contaminant dam to create the sludge lagoon.   Drainage
from the sludge lagoon could also affect the quality of the water being dis-
charged from Price Branch into Pond Fork Creek.

     Three sample points were established to determine the effects of the
various operations in the valley.  Figure 31 is a map of Price Branch
showing the location of the various sampling points as well as the location
of the demonstration mine and the main portal of Island Creek's Pond Fork
Mi ne.

     Sample point "A" represents the drainage water above the demonstration
mine site and was taken at the discharge of the culvert under the road serving
the demonstration mine site.  This water drains down the valley from the
stripped mined area above and reflects this operation.

     Sample point "B" is below the demonstration mine site and just above
a small stream draining a smaller water shed.  Strip mine spoil from the
Dorothy seam could affect this water quality.  Samples A and B represent the
                                       70

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         Location of Water
          Sampling Points
           FIGURE 31
71

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water supplied to the demonstration mine site and the waters below the  site.

     Discharge waters from the demonstration mine would affect the quality of
the water at point B.

     Sample point "C" was taken just above the mine road bridge serving the
area and is a composite of all waters draining down the valley.   This water
discharges directly into Pond Fork Creek.

     A random sampling program was conducted and all  samples were taken within
one hour of each other.  No effort was made to determine water flows nor to
correlate analyses to flows.  Tables 1 through 7 in Appendix L show the com-
parison of the results for each set of samples.   Figure 32  shows the maximum
and minimum values for each sample point.

     A review of the various tables indicates that the mining activity  in the
water shed has not materially affected the quality of water discharging into
Pond Fork Creek.  If anything, the water slightly increases in pH.  There is
little change in the water quality between sample points A  and C.
                                      72

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                                            FIGURE 32
                                     WATER ANALYSES - RANGES
CO
     Determination
M.O. Alkalinity  (CaC03)
Total Acidity  (CaC03)
Chloride  (Cl)
Sp. Conductance  (25°C) JJL mhos/cm"
pH  (units)
Calcium  (Ca)
Magnesium (Mg)
Hardness  Total
Sulfate  (SO4)
Iron Total  (Fe)
Total Matter
Suspended Matter
Dissolved Matter
Aluminum  Total  (Al)
Manganese (Mn)
                                     Point A
                                     min-max
  26-
   3-
1.49-
 149-
 6.7-
  27-
 9.6-
  61-
31.9-
0.33-
 128-
   4-
 117-

0.08-
75
14
1.87
220
7.7
27.2
19
180
74
5.0
251
31
220
5.9
0.57
            Sample Location
                Point B
                                                              min-max
  23-
   4-
1.56-
 134-
 6.7-
19.2-
13.4-
  65-
27.2-
0.29-
  49-
  19-
  29-

0.07-
60
24
1.84
200
7.7
27.0
16
170
67.0
55
2,640
2,519
212
63.5
1.6
     All  results  reported as parts per million (ppm)  unless otherwise noted,

     Point A - above Demonstration Mine Site
     Point B - below Demonstration Mine Site
     Point C - drainage from valley before entering creek
Point C
min-max

 24-52
  2-8
                                                                                   7.2-7.5
                                                                                    73-128
                                                                                 44.6-86.2
                                                                                   2.0-21
                                                                                   213-1,020
                                                                                    59-841
                                                                                   179-220
                                                                                   3.0-30.0
                                                                                 0.22-0.88

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                                SECTION XIV

                         DEMONSTRATION MINE DESIGN

     As a result of the Phase I study, the Pond Fork Mine of Island Creek
Coal Company was selected as the site for the proposed demonstration mine.
The demonstration mine is to be located in the Dorothy seam approximately  3500
feet around the mountain from the main portal to the Pond Fork Mine and
approximately one mile from the Phase II office.  The outcrop of the Dorothy
seam had been auger mined.  However, a block of coal  was left unaugered  for
the portal to the demonstration mine.  An access road is available to the  site
and a major part of the grading has already been completed.   Additional  site
preparation will be required to provide adequate drainage in the area.
Approximately 150 feet above the Dorothy outcrop, the Number Five Block  coal
seam had also been auger mined.  Spoil from the Number Five Block operation
was pushed down over the mountain and is a threat to the demonstration mine
site.  This must be removed prior to the construction of the mine.

     The demonstration mine site is located at the headwaters of the Price
Branch of Pond Fork Creek.  All coal removed from the mine will  be trucked
down the hill to the present preparation plant for the Pond Fork Mine.   Power
is available within 500 feet of the mine site.  However, water must be piped
to the site.

     Each recommendation of the Phase I study was reviewed and in a few  cases,
changes were made.  Two gas generators were used instead of the previously
recommended gas holder.  Continuous purging of the gas locks was used rather
than the demand purging proposed in Phase I.  The double hopper coal removal
system was replaced with a water seal system.  Figure 33 shows the general
arrangement of the demonstration mine.

Gas Blanketing Systems

     A review of blanket gas requirements in the Phase I report indicated  that
the gas holder was expensive and unnecessary.  In its place, two inert gas
generators were used to meet the peak demands required during the locking  of
personnel and equipment into the mine.  In addition, a high pressure gas supply
was used to purge the personnel lock at the refuge station.   This required the
use of an inert gas compressor and receiver.

     A review of the various inert gas generators available indicated that most
generators used direct contact with water to cool the inert gas and the  exit
gas from the generator was saturated with water.  The inert gas generators
chosen for the demonstration mine utilizes indirect cooling of the exhaust gas
and the gas  is not necessarily saturated with water.  Two 40,000 cubic feet
                                      74

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per hour gas generators were selected.   The size was dictated by the criteria
that one thousand cubic feet per minute of purged gas be used when purging
the personnel and equipment locks.   This was by far the greatest single use
of blanketing gas and by satisfying these requirements, all  other gas demands
would be met.

     The two inert gas generators have  a maximum capability  of 1333 cubic feet
of inert gas per minute.  Each generator can be throttled back to produce one-
third of its normal output and still meet the inert gas criteria.   The minimum
output of the system would be obtained  by running one generator at one-third
capacity and would amount of 222 cubic  feet of blanketing gas per minute.  Each
generator can be throttled back individually or in unison to produce any volume
of gas from one-third the capacity of one generator to full  capacity of both.
The system is therefore capable of supplying 222 to 1333 cubic feet of blanket-
ing gas per minute.  If less than 222 cubic feet of gas per  minute is required,
the unused portion will be vented to the atmosphere and only that gas required
for the system will be used.

     To supply the compressed gas to operate the personnel lock at the refuge
station, a 200 cubic feet per minute gas compressor was used to maintain a 100
pounds per square inch pressure in an 8000 cubic foot gas receiver.   The
discharge of the receiver was piped into the mine to operate the gas lock at the
refuge station.  The gas compressor will automatically keep  the pressure in
the receiver at 100 pounds per square inch as a result, there will  be enough
gas in the receiver to operate the gas  lock in the refuge station for approxi-
mately five cycles, even under power failure conditions.   Under the maximum
gas generator output, 1000 cubic feet per minute of gas is required to operate
the personnel lock, 200 cubic feet per  minute for the gas compressor,
and the remaining 133 cubic feet would  be available to maintain the in-mine
pressure.

     One of the ultimate goals of the demonstration mine is  to evaluate the
humidity increase within the sealed mine.  It is predicted that 100% humidity
will be reached and maintained in the mine at all times.   The dew point of the
blanketing gas from the selected gas generators is therefore considered critical.
To eliminate this variable, each gas generator was equipped  with a refrigerant
dryer capable of drying the total gas flow from the generator to produce a
40°F dew point gas for in-mine use.  This represents a gas containing 40%
relative humidity at 70°F, which is the projected operating  temperature of the
demonstration mine.

     A review of the various fuels available for operating the inert gas genera-
tors showed that natural gas was not available.  It was therefore necessary  to
consider either liquid petroleum gas or fuel oil.  Liquid petroleum gas was  the
selected fuel for firing the inert gas  generators.  The fuel oil added contamin-
ants to the gas stream which were undesirable.  Figure 34 is the flow sheet
showing the blanketing distribution system.
                                       76

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Demonstration Mine
    Inert Gas
   Flow Diagram

    FIGURE  34

-------
Coal Removal System

     Phase I recommended a double hopper system with inert gas purging to remove
the coal batchwise from the mine.  Further investigation into this problem re-
sulted in the design of a water seal that permitted the continuous removal of
the coal from the mine while still maintaining a positive seal on the mine.   A
standard drag tank used in coal preparation plants throughout the coal industry
was determined to be a suitable piece of equipment to accomplish this goal.
Figure 35 shows the general arrangement of the water seal.  Figures 36 and 37
show further details of the system.

     The coal is discharged off the end of the belt conveyor behind the mine
seal inside the mine into a chute which conducts the coal into the side of the
drag tank and below the water level.  The water seal is maintained in the coal
chute.  The drag conveyor removes the coal from the tank as rapidly as the belt
conveyor feeds it into the chute.  The coal  is discharged onto a stacking con-
veyor which elevates the coal  and stacks it on the ground.  A make-up water
system assures a sufficient quantity of water at all times to maintain the seal.
All runoff water is recovered for reuse.

Dust and Heat Control
     The dust and heat control  systems incorporated into the mine design are
basically those recommended in  the Phase I report.   The mine atmosphere will
continually circulate through the mine using a standard mine ventilation fan.
Ducts were provided so that the air flows out one entry, through the fan and
returns to the mine through another entry.  The ducting was designed so that
it could be rapidly converted to a normal mine ventilating system.

     The initial heat control system recommended in Phase I included the use of
a 50 ton air conditioning unit  for humidity control in the mine.   Various systems
were reviewed and a standard, air-cooled, air conditioning unit was  chosen for
the system.  This packaged unit is not directly in  the air stream, but in a
bypass stream and can be used or bypassed as the test requirements for the
project dictate.

     A standard Rolomatic off-the-shelf dust collector was incorporated into the
air flow pattern as it provided a minimum resistance to the air flow in the
system.  In all cases, all equipment was installed  downstream of the ventilating
fan in order to minimize the negative pressure on the suction pressure in the
entire system.

Gas Locking System

     The Phase I report called for the demand purging of the various locks
incorporated in the system.  This meant that the lock was purged only when some-
body wanted to pass through and the purge cycle had to be manually activated.
This would be the ideal operating sequence for these locks to conserve purge gas.
However, in-leakage from the mine and the refuse station and the outside into
the respective locks could be a problem.  As a result, an automatic  purge
system was incorporated into the mine design.
                                       78

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          Water Seal

         Section View


          FIGURE 36

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                                             sr-
                                               Water Seal
                                            Elevation Section

                                                FIGURE 37

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     This system incorporated an automatic carbon dioxide analyzer using  a
reference cell to compare the composition of the gas in the gas  lock to the
composition of the gas being used to purge the lock.  Once these two compositions
were equal, the purge cycle would shut down.  Should there be any leakage into
the gas lock that would change the composition of the gas in the lock, the
purge cycle would automatically restart and purge the lock until once again  the
analyses of the two gases were the same.  Interlocks were provided to prevent
the activation of the purge cycle while entering the gas lock.

     By using the automatic purge cycle, the leakage of air from one area to the
other will be held at a minimum, and it in no way overburdens the capabilities
of the gas generators to supply the gas.

     The gas lock at the refuge station will operate from the 100 pounds  per
square inch supply of high pressure gas which will  deliver 1000  cubic feet per
minute of gas to the lock.  High pressure gas was chosen as the  least costly
route to accomplish the job.  This lock will utilize the automatic purge  system
as described.  The only difference between it and the personnel  lock is the  use
of the high pressure gas.

Refuge Station

     The Phase I report indicated that a bore hole system would  be used to
ventilate the refuge station.  A review of this concept, both from an engineer-
ing and cost standpoint, indicated that for this particular instance it would
be better to ventilate the refuge station by running ducts from  the mine  mouth
to the refuge station.  Fresh air from the mine mouth would be blown into the
refuge station and the exhaust air returned by the same route.   This scheme  was
incorporated into the demonstration mine.  In all cases, standard off-the-shelf
equipment was used.

Instrumentation

     A complete instrumentation system was developed to control  the blanketing
gas system.  A similar system was developed to control  the cooling water
circuitry required for the inert gas generators, refrigerant dryers, air
compressor, and water seal.  The water system incorporated the use of a cooling
tower in order to minimize demands on make-up water.  Figure 34  is the flowl
diagram showing the inert gas system and Figure 38 is the flow diagram for the
water system.

     Additional instrumentation recommended in the Phase I report was provided
to continuously monitor the various atmospheres in the mine, in  the gas lock,
in the personnel lock, and in the refuge station.  Additional instruments to
measure gas flow in the mine, dew point and temperature were included.  A
complete weather station was also incorporated into the system in order to
evaluate the effects of weather changes on the operation of the  mine.

     Figure 39 shows the monitors and air lock instrumentation incorporated
in the mine.
                                       82

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                                                                      Demonstration Mine
                                                                        Water System
                                                                        Flow Diagram

                                                                          FIGURE  38

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                                                                        Demonstration Mine
                                                                      Monitor and Interlock
                                                                        Instrument Diagram


                                                                             FIGURE 39

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     The demonstration mine was designed to be a one section mine operated
by one crew one shift per day for five days per week.  This was the recommenda-
tion of the Phase I report and was used in designing the demonstration  mine.
The change from the gas holder to two inert gas generators and the requirements
for ]000 cubic feet per minute purge rate in the gas locks dictated the size
of the gas generating equipment.  The gas requirements as calculated in the
Phase I report were 400,000 cubic feet per day.  The inert gas generators have
the capability to supply five times this amount of gas or approximately two
million cubic feet per day.  This will enable the rapid purging of the  mine
initially and has the capacity to support a three shift operation.

Summary

     Based on the above changes, the design of a demonstration mine was
developed in a suitable manner so that a reliable estimated cost of the mine
could be developed.  Prior to the construction of the mine, additional  detailed
drawings will be required.  The drawings listed in Appendix I were submitted  to
the Environmental Protection Agency and constitute the complete design  of the
demonstration mine.
                                      85

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                                 SECTION XV

                          DEMONSTRATION MINE COSTS

     The Demonstration Mine was designed for the purpose of determining the
equipment and details required to construct and operate a mine under controlled
atmospheric conditions in order to better understand how the mine would
operate and to develop the associated cost to construct and operate the mine.

     It was anticipated that the end result of this Phase II would be a
tested and reliable life support system suitable for extensive testing in a
demonstration mine.  The next phase would be the construction and operation of
a demonstration mine using a full crew equipped with life support systems.
The mine would be operated for approximately six months under ventilated
conditions to further test the reliability of the system.  The oxygen would
then be removed and the mine operated under oxygen-free conditions for a
period of one year.

     This line of thinking is still valid for the testing of a reliable life
support system.  However, the crew testing under ventilated conditions should
be extended to a minimum of twelve months in order to permit any additional
modifications and changes to the system to be thoroughly evaluated.

     The overall length of the demonstration mine phase would be 48 months.
This would involve the review and updating of the existing mine design, the
preparation of detailed construction drawings, the purchase and delivery
of the equipment, and the construction of the mine and associated systems.
This would be followed by a period of miner training in the use of the life
support system and the inert gas system check-out.  These would require
approximately two years to complete.  Two twelve month in-mine test periods
would then be undertaken—one under ventilated conditions and the other
under oxygen-free conditions.  Improvements in the equipment delivery and
construction could reduce the overall length of the project.

     The following costs were developed for the construction and operation
of a demonstration mine for a period of 48 months:

Capital Costs

     Gas Blanketing Systems per design drawings           $1,154,500
     Additional Mining Equipment                             251,500
     Life Support Systems and Offices                        483,260
     Initial Capital Investment                           $1,889,260
                                      86

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Operating Costs

     Miscellaneous Supplies, Etc                             276,100
     Operating Labor                                       2,839,120
Total 48 Month Cost                                       $5,004,480

     This is an annual operating cost of $778,805, which will be reduced
through coal credits returned to the project.  See Appendix N for a
breakdown of these costs.
                                     87

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                                 REFERENCES

1.  Bradley, S. A. "Summary Report of Commonwealth of Pennsylvania, Department
    of Health Industrial Fellowship, No's 1 through 7," Mellon Industrial
    Fellowship No. 326B, 1954.

2.  Bell, W. E., "Studies of the Effect of Gas Atmospheres on Pyrite Oxidation,"
    Final report under Federal Water Quality Administration Contract No.
    14-12-404 to Cyrus Wm.  Rice Division, NUS Corporation, Pittsburgh, Pennsy-
    lvania, April, 1969.

3.  "Gas Requirements to Pressurize Abandoned Deep Mines—A Study of the Use
    of Inert Gases to Eliminate Acid Pollution from Abandoned Deep Mines,"
    A report of the Commonwealth of Pennsylvania, Department of Mines and
    Mineral Industries under Project No. CR-81, Federal Water Quality Adminis-
    tration  Project No. WPRD-227, 1968.

4.  "Space Cabin Atmospheres Part 1 - Oxygen Toxicity," National Aeronautics
    and Space Administration SP-47, 1964.

5.  "Bioastronautics Data Book," National Aeronautics and Space Administration
    SP-3006, 1964.

6.  "Space Cabin Atmosphere Part 3 - Psychological Factors of Inert Gases,"
    National Aeronautics and Space Adnrinstration SP-117, 1967.

7.  "Portable Life Support Systems," Ames Research Center Conference, May,
    1969, National Aeronautics and Space Administration SP-234, 1970.

8.  Jackson, J. D., and Blakely, R. L., "Application of Adsorption to Space-
    craft Life Support Systems," Missile and Space Systems Division, Douglas
    Aircraft Company, Inc.

9.  Mills, E. S., G. V. Colombo, and R. A. Neustein, "Evaluation of Carbon
    Dioxide Sorption Techniques for Hydrospace Application," Douglas Aircraft
    Company, Independent Research and Development Program, Account No. 81641-001.

10. "Engineering Criteria for Spacecraft Cabin Atmosphere Selection," Advanced
    Biotechnology and Power Department, Missile and Space Systems Division,
    Douglas Aircraft Company, Inc., Douglas Report DAC-59169, November, 1966,
    under National Aeronautics and Space Administration Contract No. NASW1371.

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11.  Potter, A. E., Jr., and B. R. Baker, "Static Electricity in the Apollo
    Spacecraft," Manned Spacecraft Center, Houston, Texas, National
    Aeronautics and Space Administration Report No. TND-5579, December, 1969.

12.  Lorenz, Walter C., and Edward C. Tarpley, "Oxidation of Coal Mine Pyrites,"
    Bureau of Mines RI 6247, 1963, 13pp.

13.  "Stream Pollution by Coal Mine Drainage in Appalachian," U.S.D.I., FWQA,
    Cincinnati, Ohio, Revised 1969.

14.  Herndon, L. K. and W. W. Hodge, "Coal Seams of West Virginia and Their
    Drainage," Proc. West Virginia Academy of Science, Vol. 9 pp. 39-61,
    Feb., 1936.

15.  "Drainage from Bituminous Coal Mines,"   Engineering Research Bulletin 25,
    West Virginia University, February,  1954.

16.  "Feasibility Study of Mining Coal in an Oxygen-Free Atmosphere," Final
    report under Federal Water Quality Administration Contract No.  14010 DZM
    to Island Creek Coal Company, Hoi den, West Virginia, August, 1970.
                                     89

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                                PUBLICATIONS

1.  Rice, J. K. and R. C. Taliaferro, "Mining in an Inert Atmoshpere,"
    Presented at the 1970 Coal Convention and Exposition, American Mining
    Congress, Cleveland, Ohio, May, 1970.

2.  Rice, J. K., "The Use of Inert Gas to Eliminate Acid Pollution by
    Abandoned Active Deep Mines," Presented at the Third Symposium on Coal
    Mine Drainage Research, Pittsburgh, Pennsylvania, May, 1970.

3.  "Inert Atmosphere in Mines Could Abate Acid Drainage," Chemical and
    Engineering News, 48, May 18, 1970, pp. 33-35.

4.  Rice, J. K., "Health and Safety When Mining in an Inert Gas Atmosphere,"
    Statement to the Subcommittee on Labor, Senate Committee on Labor and
    Public Welfare on Coal Mine Health and Safety, 1969.

5.  Rice, J. K., "Acid Mine Drainage Abatement from Deep Mines by Inert Gas
    Blanketing," Testimony before Water Pollution Advisory Board, Pittsburgh,
    Pennsylvania, 1968.
                                      90

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                                   TECHNICAL REPORT DATA
                            (Please read Instructions on the reverse before completing)
1. REPORT NO.
 EPA-600/7-78-080a
                                3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
                                                            5. REPORT DATE
  Testing  Program for Mining Coal  in  an  Oxygen Free
  Atmosphere  -  Volume 1
                                  May 1978 issuing  date
                                6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)

   R.  C.  Taliaferro and  Don  Motz
                                8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS
                                                            10. PROGRAM ELEMENT NO.
  Island Creek  Coal  Co.
  Hoi den, WV  25625
Cyrus Wm. Rice  Division
NUS Corporation
Pittsburgh,  PA  15220
   INE  623B
11. CONTRACT/GRANT NO.
                                                              Grant  14010  DZM - Phase II
12. SPONSORING AGENCY NAME AND ADDRESS
  Industrial Environmental  Research Lab. - Cinn, OH
  Office of Research and  Development
  U.S.  Environmental Protection Agency
  Cincinnati,  Ohio 45268	
                                 13. TYPE OF REPORT AND PERIOD COVERED

                                   Final	
                                 14. SPONSORING AGENCY CODE
                                     EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
       A systems evaluation was undertaken  to  demonstrate the ability of miners
  wearing life support systems to operate conventional mining equipment and  to mine
  coal  at a test section  in an active ventilated mine.  Their ability to operate
  mining equipment  and to perform other  in-mine  tasks was successfully demonstrated.
  No major difficulties were encountered in  performing these tasks and the miners
  reported they had never been that comfortable  before when working in a mine.

       The life support system provided cool,  clean  air for the miner and did not
  hamper his ability to work.   The system was  adequate to demonstrate the miner's
  ability to mine coal  while wearing a life  support  system.  However, mechanical
  failures in the chiller and rebreather module  were experienced.  Additional work  to
  develop a totally reliable life support system and further testing under ventilated
  conditions are required before testing in  an oxygen  free atmosphere.

       Due to the size  of the  Appendices, they have  been  published in a  separate volume,
  available from the  National  Technical  Information  Service (NTIS), 5285 Port Royal
  Road,  Springfield,  Virginia,  22161.   A list of the Appendices  has been included
  in  the contents of  this volume.
17.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                              b.lDENTIFIERS/OPEN ENDED TERMS
                                                                           COSATi Field/Group
 Underground mining
 Coal mines
 Life support system
                    Oxygen-free mining
                    atmosphere
                    95E
                    48A
                    940
18. DISTRIBUTION STATEMENT


 Release to public
                   19. SECURITY CLASS (This Report)
                     Unclassified
             21. NO. OF PAGES
                   101
                   20. SECURITY CLASS (This page)

                     Unclassified	
                                              22. PRICE
EPA Form 2220-1 (R«v. 4-77)   PREVIOUS EDITION is OBSOLETE

                                           91
                                                                      * u.i OMWOT rame omcb \m— 757 -1« /684S

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