Managing Extreme Risk by preventing flammable gas explosions. Michael van Niekerk

Transcription

1 Managing Extreme Risk by preventing flammable gas explosions Michael van Niekerk

2 Eliminating methane explosion risk ExploSpot eliminates the risk of methane explosions by stopping the explosion before it develops It is a permanent sentinel able to detect and react to a methane combustion within 3 milliseconds ExploSpot extinguishes an ignition within 100 milliseconds, by creating a complete barrier and extinguishing the source ExploSpot prevents lethal overpressures ( kpa) and temperatures (100 C > 0.5s) from being reached, as well as toxic gas build up from occurring.

3 How ExploSpot works Armed mode System always ready Self check BITE (Built In Test Equipment) Detector auto water flush system Event Flame detected and verified < 3 milliseconds Valves open < 5 milliseconds Extinguishant released from nozzles < 10 milliseconds Barrier formed < 100 milliseconds Barrier sustained for 4 seconds Events logged: detector activated, valves opened, pressure released Optional cutter trip

4 Typical explosion pressure wave

5 Current ExploSpot Deployment South Africa Collieries (17 systems) Sasol Syferfontein Sasol Middelbult Sasol Middelbult West Sasol ithembulethu Sasol Brandspruit Anglo New Denmark Major China Collieries (400 roadway, 28 long wall, 27 roadheaders, 328 methane pump stations) Daning, Shanxi Gaoping Tangan, Shanxi Tiefa, Liaoning Dongfeng, Heilongjiang Datong, Shanxi

6 SA 5 confirmed events ExploSpot History Okhozini (2002), Syferfontein (2003, 2005, 2010), Arnot (2005)

7 Ex / IS / MA Certification The ExploSpot System is designed to comply all the relevant Ex approvals such as: IEC :1999 and SANS/IEC :2005 for IS equipment IEC :2005 and IEC :2005 for flameproof equipment South Africa SAEx China CMEx MA Spain GEN

8 ExploSpot application ExploSpot equipment is approved for: Machine mounted systems (CM or Roadheaders) Long wall mining operations, and Standalone (fixed or mobile) roadway barriers Gas pumping stations & gas pipelines Underground substations switchgear & bus bar protection Bulk fuel storage Surface mining vehicles

9 CSIR Klopperbos explosion tests CSIR Mining Technology SIMRAC HS Design Engineering CJ Moolman, CSIR Mining Technology (Feb 2005) Project No.: SIM

10 Unsuppressed explosion

11 Unsuppressed explosion

12 Unsuppressed explosion

13 ExploSpot suppressed explosion

14 Suppressed explosion

15 3 millisecond reaction time

16 Suppressed explosion

17 Klopperbos 20m Test tunnel

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20 DEG CENTIGRADE Unsuppressed temperature intensity TEMPERATURE AT OPERATOR TIME IN MILLI-SECONDS

21 DEG CENTIGRADE Suppressed temperature intensity TEMPERATURE AT OPERATOR TIME IN MILLI-SECONDS

22 Roadway gas ignitions

23 Speed in m/s Unsuppressed explosion: Flame speed Speed Graph for a standard unsuppressed explosion Distance in meters

24 Passive Roadway Safety Passive stone dust or water trough barriers require a shockwave to activate

25 Stone dust bag test results 100m reached in <1.0 s 180m reached in <1.5s Temp > 500 C sustained Pressure > 400kPa

26 Stone dust bags: Flame speed

27 ExploSpot Active Roadway Barrier

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29 SPEED (m/s) ExploSpot Suppressed Explosion at 30m SPEED GRAPH TEST DISTANCE IN METERS ExploSpot eliminates the unsafe work area so that it is safe to work up to the workface ExploSpot eliminates the build up of toxic gasses, pressure and temperature build up

30 Comparison of active & passive barriers

31 Longwall shipping container Longwall Solution

32 Longwall Workshop Installation

33 Longwall Underground Installation

34 Longwall Underground Installation

35 Longwall Operational Underground

36 Flammable Gas Pipelines

37 Pipeline system Detector collar Nozzle array Cylinders

38 ExploSpot CM components Detectors Control box Cylinders Nozzles Wiring Piping

39 Angle of view and barrier closure

40 Detector layout on bridge JoyGlobal B / C layout Control box

41 Cylinder Fitment in bumpers Nozzle layout Spray pattern

42 Joy AAA Layout

43 Non-optimal integration

44 Roadheader total integration with cooperation from OEM

45 Space optimisation Integrated cylinders Integrated nozzles and detectors

46 ExploSpot Maintenance To comply with SANS 1475 (servicing fire extinguishers) and due to the highly corrosive environment and rough operating conditions ExploSpot requires the following strict maintenance program: Daily pre-shift inspection CM operator Weekly inspections ExploSpot Field Technician Monthly service ExploSpot Field Technician Quarterly service - ExploSpot Field Technician Annual service - ExploSpot Field Technician

47 Impact of a lack of servicing

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50 Risk assessments Initial risks controls suggestions = Remaining risk

51 Thank you Questions? Michael van Niekerk