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Development and Development and Assessment of Controls Assessment of Controls
SessionSession
Coated Flight Bars & Mist SystemCoated Flight Bars & Mist System
Peter G. KovalchikPeter G. Kovalchik
Mining Hearing Loss Prevention WorkshopMining Hearing Loss Prevention WorkshopJune 21June 21--22, 200522, 2005
Pittsburgh Research LaboratoryPittsburgh Research Laboratory
CollaboratorsCollaborators
Coated Flight BarsCoated Flight Bars
C.U.E. Inc.11 Leonberg Road
Cranberry Township, Pa. 16066-3601 U.S.A.
Phone 724-772-5225Fax 724-772-5280
Web: www.cue-inc.com
PROPERTIESPROPERTIES•• Polyurethane Material Polyurethane Material -- (PO(PO--650)650)•• Durometer Durometer -- 84A 84A •• Compression Set Compression Set -- 45% max. 45% max. •• Ultimate Tensile Strength Ultimate Tensile Strength -- 6000 psi6000 psi
Polyurethane Coating (PO-650)
• Chain flight bars were coated with a durable polyurethane damping material.
• Objectives:• Minimize impact noise• Minimize scrapping noise
Note: Mention of specific brands does not imply endorsement by NIOSH.
Reverberation ChamberReverberation Chamber
Joy ChainJoy Chain(uncoated)(uncoated)Sound Power: 118 dB(A)Sound Power: 118 dB(A)
Joy ChainJoy Chain(coated)(coated)Sound Power: 111 dB(A)Sound Power: 111 dB(A)
Sound Power reduction of 7 dB(A)
UNCOATED CHAIN
01/24/04
ENLOW FORK
30 INCH UNCOATED FLIGHT BARS ENLOW FORK
Crosscut
01/24/04 dB(A)
COATED CHAIN
01/24/04
30 INCH COATED FLIGHT BARS ENLOW FORK
Crosscut
01/24/04 dB(A)
DIFFERENCE BETWEEN 30 INCH UNCOATED FLIGHT BARS &
COATED FLIGHT BARSENLOW FORK
Crosscut
01/24/04 dB(A)
.633.481,269.9229.796
.42.642,015.9303.198
.312.32,539.8348.299
.21.744,031.7459.5101
.131.326,400.0606.3103
.08110,159.4800.0105
0.060.8712,800.0919.0106
0.101.158,063.5696.4104
0.161.525,079.7527.8102
0.252.003,200.0400.0100
0.503.031,600.0263.997
0.794.001,007.9200.095
1.004.59800.0174.194
2.006.96400.0114.991
2.528.00317.5100.090
4.0010.56200.075.888
8.0016.00100.050.085
16.0024.2550.033.082
25.4032.0031.525.080
NIOSH NIOSH HoursHours
MSHA MSHA HoursHours
NIOSH NIOSH Dose Dose (%)(%)
MSHA DoseMSHA Dose(%)(%)
Sound Sound Pressure Pressure
Level dB(A)Level dB(A)
UncoatedChain
CoatedChain
02/09/04The shift production data from 1/24 to 2/09 is ----- shifts with 12,500 tons mined.02/09/04
The shift production data from 1/24 to 2/09 was 22 shifts with 12,500 tons mined.
The shift production data from 1/24 to 7/16 was 164 shifts with 71,826 tons mined.
98 dB(A) at Tail Roller
7/16/04
SummarySummary•• Sound Power Reduction of 7 dB(A)Sound Power Reduction of 7 dB(A)•• Underground Sound Level Reduction of 4 Underground Sound Level Reduction of 4
dB(A)dB(A)•• Durability Durability -- Minimal Wear after 6 months Minimal Wear after 6 months
(mainly on the tips)(mainly on the tips)•• Longer Chain LifeLonger Chain Life•• Allowable Exposure Time was Increased Allowable Exposure Time was Increased
by 1 Hourby 1 Hour•• Promising noise controls on MSHA Promising noise controls on MSHA
Program Information Bulletin P04Program Information Bulletin P04--1818
Mist Drilling SystemMist Drilling System
Mist System SpecificationMist System Specification
•• Air Air –– Flow : 20 cfmFlow : 20 cfm–– Pressure: 110 psiPressure: 110 psi
•• WaterWater–– Flow : 1 gal/minFlow : 1 gal/min–– Pressure: 110 psiPressure: 110 psi–– Water Tank: 180 Water Tank: 180
galgal
•• OperationOperation–– Air & Water Air & Water
pressures drop to pressures drop to 96 psi. 96 psi.
80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft.
80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft.
80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft. 80ft. X80 ft.
19 ft.
19 ft.
19 ft. 19 ft. 19 ft. 19 ft.
19 ft. 19 ft. 19 ft. 19 ft.
A B C D E
TILER #1 MINETILER #1 MINEMine Height 4 ft.
Coal Seam 32 to 40 inches
80ft. X 80 ft.
19 ft.
C
TILER #1 MINETILER #1 MINEDrill PlanDrill PlanMine Height 4 ft.
Coal Seam 32 to 40 inches
80ft. X 80 ft.
X X X X
X = Drill Holes
X X X X
X
X
X X X
X X X
Vacuum DrillingNoise Measurement
Mist DrillingNoise Measurement
EvaluationEvaluation•• Two Fletcher Roof Ranger IITwo Fletcher Roof Ranger II--13 roof bolting 13 roof bolting
machinesmachines–– One with standard dual boom setup for vacuum One with standard dual boom setup for vacuum
drillingdrilling–– One with standard dual boom setup for wet drilling One with standard dual boom setup for wet drilling
with a Joy mist Systemwith a Joy mist System•• DrillingDrilling
–– Hole depth 5 ftHole depth 5 ft–– 1 in. bits1 in. bits–– 3 ft round drill steel starter, then two 3 ft hex drill 3 ft round drill steel starter, then two 3 ft hex drill
steel to finish.steel to finish.–– Rotation & Thrust Rotation & Thrust –– Max?Max?
ROOF RANGER II-13Fletcher’s Number one seller
approximately 1,281 sold in last 40 years
Water Tank 180 gal.
Mist Controller
JOY MIST SYSYEM
Compressor
JOY MIST SYSYEM
Mist Controller
Summary Summary -- Underground Sound Underground Sound Pressure MeasurementsPressure Measurements
DrillingDrilling
Mist System Mist System turned on, No turned on, No
drillingdrilling
IdlingIdling
Roof Bolting Roof Bolting Machine Machine
OperationOperation
9999101101
8888NANA
82828282
Standard Standard RRII (Mist RRII (Mist System)System)dB(A)dB(A)
Standard Standard RRII RRII
(Vacuum)(Vacuum)dB(A)dB(A)
.633.481,269.9229.796
.42.642,015.9303.198
.312.32,539.8348.299
.21.744,031.7459.5101
.131.326,400.0606.3103
.08110,159.4800.0105
0.060.8712,800.0919.0106
0.101.158,063.5696.4104
0.161.525,079.7527.8102
0.252.003,200.0400.0100
0.503.031,600.0263.997
0.794.001,007.9200.095
1.004.59800.0174.194
2.006.96400.0114.991
2.528.00317.5100.090
4.0010.56200.075.888
8.0016.00100.050.085
16.0024.2550.033.082
25.4032.0031.525.080
NIOSH NIOSH HoursHours
MSHA MSHA HoursHours
NIOSH NIOSH Dose Dose (%)(%)
MSHA DoseMSHA Dose(%)(%)
Sound Sound Pressure Pressure
Level dB(A)Level dB(A)
Vacuum
Mist
Penetration Rate = 1.18 in/secPenetration Rate = 1.18 in/secPenetration Rate = 1.07 in/secPenetration Rate = 1.07 in/sec
Number holes / Allowable Number holes / Allowable Exposure = 162 holesExposure = 162 holes
Number holes / Allowable Number holes / Allowable Exposure = 112 holesExposure = 112 holes
Dose per hole = .6% per holeDose per hole = .6% per holeDose per hole = .9% per holeDose per hole = .9% per hole
Drilling Time = 51 secDrilling Time = 51 secDrilling Time = 56 sec.Drilling Time = 56 sec.
Hole depth = 60 in.Hole depth = 60 in.Hole depth = 60 in.Hole depth = 60 in.
Standard RRII Standard RRII (Mist System)(Mist System)
Standard RRII (Vacuum)Standard RRII (Vacuum)
MISTWET
Less water than wet drilling
SummarySummary
•• Promising noise controls on MSHA Promising noise controls on MSHA Program Information Bulletin P04Program Information Bulletin P04--1818
•• Longer bit lifeLonger bit life•• Less waterLess water•• Allowable Exposure Time was Allowable Exposure Time was
IncreasedIncreased
For more informationFor more information
Peter G. KovalchikPeter G. Kovalchik
Phone: 412Phone: 412--386386--6098 Fax: 4126098 Fax: [email protected]@cdc.gov
www.cdc.gov/niosh/miningwww.cdc.gov/niosh/mining
Pittsburgh Research LaboratoryPittsburgh Research Laboratory
