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By Michael J. Pazuchanics, Thomas J. Fisher, John J. Sammarco, Jeffrey H. Welsh

This report (An Introduction to Safety) is the first in a nine-part series of recommendations addressing the functional safety of processor-controlled mining equipment. It is part of a risk-based system safety process encompassing hardware, software, humans, and the operating environment for the equipment's life cycle. Figure 1 shows a safety framework containing these recommendations. The reports in this series address the various life cycle stages of inception, design, approval and certification, commissioning, operation, maintenance, and decommissioning. These recommendations were developed as a joint project between the National Institute for Occupational Safety and Health and the Mine Safety and Health Administration. They are intended for use by mining companies, original equipment manufacturers, and aftermarket suppliers to these mining companies. Users of these reports are expected to consider the set in total during the design cycle. • 1.0 Safety Introduction.—This is an introductory report for the general mining industry. It provides basic system/software safety concepts, discusses the need for mining to address the functional safety of programmable electronics, and includes the benefits of implementing a system/software safety program. • 2.1 System Safety and 2.2 Software Safety.—These reports draw heavily from International Electrotechnical Commission (IEC) standard 61508 and other recognized standards. The scope is "surface and underground safety mining systems employing embedded, networked, and non-networked programmable electronics." System safety seeks to design safety into all phases of the entire system. Software is a subsystem; thus, software safety is a part of the system's safety. • 3.0 Safety File.—This report contains the documentation that demonstrates the level of safety built into the system and identifies limitations for the system’s use and operation. In essence, it is a "proof of safety" that the system and its operation meets the appropriate level of safety for the intended application. It starts from the beginning of the design, is maintained during the full life cycle of the system, and provides administrative support for the safety program of the full system. [ ]

Jan 4, 2001

By Allen D. Look, Alan A. Sharp

"Churn drills for blast-hole drilling are important to the operation of most open-pit metal mines, but certain hazards are created through their use that cause fatal and nonfatal accidents.2/ The purpose of this circular is to present a code of safe practice prepared and followed at a large Arizona open-pit copper mine, where safety is recognized as a definite operating problem. Such a code, based upon a thorough study of available published information as well as practical experience gained from accidents and near accidents, is the result of considerable effort and monetary expenditure. It is hoped that other operations using churn drills may benefit by the code presented, either in comparison with existing rules or in the preparation of new operating instructions.The code presented is in use at the Morenci Branch of the Phelps Dodge Corn., Morenci, Ariz. Similar codes are used at the New Cornelia Branch, Ajo, Ariz., and in the waste-pit operation at the United Verde Branch, Jerome, Ariz.The authors gratefully acknowledge the cooperation of the Phelps Dodge Corp., whose personnel made: possible the collection of information included in this circular. Special acknowledgment is due Paul Simmons, safety engineer, and 3. U. Larsen, general drilling and blasting foreman, Morenci Branch, Morenci, Ariz.The importance of churn drills in Arizona mining is apparent when it is realized that at all the open-pit copper mines blast holes are drilled with this equipment. At Morenci, approximately 98 percent of the ground is broken by primary blasting of churn-drill holes.There has been a growing tendency in Arizona's copper-mining industry to change from underground to open-pit mining, with consequent increase in the use of churn-drill blast holes for primary blasting.3/Thirty-three churn drills are in use at Morenci for blast-hole drilling. The drills operate with 440-volt alternating current, and trailing drill cables, in 500-foot sections, connect with the portable drill transformer station.4/ Three Diesel-driven churn drills for drilling prospect holes also are in use. About 25 churn-drill shifts are operated currently on a three-shift basis. Ordinarily, a two-man crew is assigned to each drill; however, with prospect-drill crews a third man is added to handle the sampling.Benches are carried at a uniform height of 50 feet. Churn-drill holes are 9 or 12 inches in diameter and about 60 feet deep. The holes are 18 feet apart in hard waste and 21 feet in soft waste and ore, with toes from 11 to 13 yards at the shovel grade. Both the hole spacing and the toe have been increased gradually, until they are now 2 yards longer than in 1940. The average ground broken per hole is 3,500 tons, or 60 tons of ore per foot of hole drilled. The holes are drilled 10 feet below the bench to avoid leaving hard bottom, which requires secondary drilling and blasting.Starting with a 12-inch casing, the prospect holes average 1,200 to 1,500 feet in depth and terminate with 6-inch casing; the deepest hole drilled to date went to 1,735 feet.In addition, churn-drills are used at Morenci to drill blast holes in the silica pit, limestone quarry, and the tailings dam. Other irregular applications are the drilling of holes to set trolley roles and for concrete piling in building foundations."

Jan 1, 1950

By Deborah A. Spotts

Researchers at the Bureau of Mines have developed a technique for re- generating chromic acid-sulfuric acid etching solutions used in metal surface treatment operations. The technique utilizes a diaphragm cell equipped with a cation-selective membrane to oxidize cr3+ to cr6+ at the anode and to remove copper, the major metallic contaminant, at the cathode. Normally, spent etchant is discarded after approximately 3 days of use. Using the electrolytic cell, the etchant can be used for a year without replacement, From data obtained from industrial-scale cells, the installation of a regeneration cell with a 1,000-gal catholyte- holding tank has been estimated to save at least $240 per day, The payback period for the investment is estimated to be about 10 mo or less. Because the magnitude of these cost savings will vary at different locations, several graphs are presented to aid in calculating payback for a specific site. Using these graphs and the capital costs presented in this study, the payback period can be determined for installing a regeneration cell with a 500- or a 1,000-gal catholyte-holding tank in an existing surface treatment plant.

Jan 1, 1983

By C. G. Kirkland

An apparatus for determining trace impurities in Grade-A helium by mass spectrometer methods was designed and built by the Federal Bureau of Mines. Grade-A is the designation for helium commercially produced by the Bureau. Its nominal purity is 99.995 percent. The device, following a suggestion by Deaton, concentrates the impurities in the helium by freezing them out in a coil-and-trap assembly cooled by liquid helium. A known volume of helium is passed through the trap, the concentration ratio determined, and samples of the concentrated impurities are analyzed by mass spectrometer methods. The apparatus has been in service for approximately 20 months and has satisfactorily met all requirements. Over 200 analyses were made of helium contained in conventional cylinders, obtained from the Amarillo, Exell, Otis, and Navajo Helium Plants, during the 6-month period ending March I, 1959. Total impurity concentrations, in parts per million, were as follows: Amarillo, 19.1; Exell, 17.1; Otis, 11.3; and Navajo, 6.6. Neon and nitrogen were the major impurities. Complete data are shown in table 4 in the body of this report.

Jan 1, 1960

By Connie S. Musulin

The Bureau of Mines conducted an experiment at Exxon Mineral Co.'s Buffalo Shaft Operation to determine the time required for radon concentrations to return to a base average after fan shutdowns. Shutdown times ranging from 5 min to 16 hr were evaluated. An equation was derived to calculate a ratio that determines the time required for the radon concentration to return to the average level that existed in the mine prior to shutdown. For fan shutdowns of 15 min or more, underground personnel should be evacuated to areas with natural downcast ventilation. For shutdowns of less than 1 hr, personnel should not return to the working area until the elapsed time is four times the shutdown, or until the working area is resampled and found safe. If the mine is not in production during weekends, the downcast fans can be turned off .from midnight Friday until 4 p.m. Sunday, and the radon daughter concentration should be below 1 WL throughout the mine by the start of the shift Monday. This fan shutdown would conserve energy and save the mining company an estimated $21,000 each year.

Jan 1, 1982

By J. D. Corrick

Research was conducted to develop operating techniques and define some of the limiting parameters for microbially converting hydrous calcium sulfate to hydrogen sulfide. The work was carried out in either glass stoppered flasks or anaerobic fermentors. Using the criteria of pH, temperature, number of bacteria per milliliter of test solution, and hydrogen sulfide produced, it was shown that hydrous calcium sulfate could be microbially converted to hydrogen sulfide at a rate of 7.3 g H2S/1 of fermentor volume per 24 hours. The various parameters defined were pH, temperature, and medium exchange rate. These were shown to be a pH range of 7.2 to 8.8, a temperature range of 30° to 35° C, and a medium exchange rate of 70 percent of the ferment or volume per 24 hours. It was also shown that a daily waste was between 50 and 77 percent as effective as sodium lactate in supporting the production of hydrogen sulfide and that by utilizing a gas to purge the fermentation system, a 1.7-fold increase in hydrogen sulfide was obtained.

Jan 1, 1970

By Carlton E. Brown, William P. Yant

"INTRODUCTION Direct visual microscopic determination of particle-size distribution and number concentration of atmospheric dust is time-consuming and trying to the eyes. By using the microscope to project images of the particles at high magnification onto a screen much of the eyestrain can be eliminated and particle-size distribution results obtained with less effort and at a considerable saving in time. It also permits simultaneous observation of the images by more than one person. Microprojection requires no more skill and very little more apparatus than is required in the use of the microscope. Anyone familiar with the microscope should be able to obtain as perfect images on the projection screen as in direct visual microscopy since the same laws and limitationsThe theory and practice of microprojection are described in detail in texts. 5/6/ The procedure has been used and found to be satisfactory for measuring the particle-size distribution of sub-sieve-size substances, such as pigments and powder 7/8/ in the same size range as that of atmospheric dust. The Bureau of Mines has used the microprojector and found it to be quite satisfactory for (1) the determination of the number concentration of atmospheric dust R.I. 3289 in samples collected by the Owens jet dust counter; (2) particle-size distribution in samples of atmospheric dust collected by the Owens jet dust counter and by the electric precipitator; and (3) the particle-size distribution of dusts, blood cells, bacteria, and pollen. Work is in progress at this Bureau on the use of the microprojector in counting impinger samples. The use of different kinds of illumination, such as reflected (dark field), polarized, monochromatic, and ultraviolet, in the projection of images of atmospheric dust particles is being considered."

Oct 1, 1935

This report, which updates and supersedes the Office of Surface Mining's 10-year progress report published in 1987, deals with the accomplishments of the regulatory and abandoned mine land reclamation programs during the first 15 years of the Surface Mining Control and Reclamation Act of 1977 (SMCRA). Part 1 is an illustrated description of on-the-ground accomplishments; Part 2 presents statistical information for the 15-year period. The data in this statistical report are organized in two sections: national statistics and state statistics. The national statistics provide an overview of coal mining and the implementation of SMCRA since 1977. The information reported for the states presents a brief description of the coal reserves in each area, accompanied by detailed statistics and graphs that relate each state to the nation as a whole. The statistics compiled in this report are from the Office of Surface Mining's files, computer data systems, and annual reports. During the early years of the program, many of the data categories were evolving and changing; therefore, data reported over the 15-year period are not complete for all states for all years, and where data was unavailable or zero, a dash (-) is shown for that item. The data sources used to compile the tables and graphs are listed and described in detail on page 76. Due to the number of requests for this information in the past, statistical information about coal mining and its regulation will be available each year as an appendix to the Office of Surface Mining's Annual Report to Congress. Beginning in Fiscal Year 1993, this information will be compiled and published on an annual basis. For more information about this report, call or write the: Public Affairs Office Office of Surface Mining 1951 Constitution Ave., N. W. Washington, D.C. 20240 (202) 208-2553

Jan 1, 1992

By W. A. Grosh

The Bureau of Mines began a comprehensive investigation of the old lead diggings in the Wisconsin portion of the Upper Mississippi lead-zinc field in September 1947 to determine whether enough lead was present in shallow deposits to justify exploitation by modern open-pit methods. Because of the large number of areas of surface diggings, it was necessary to limit the investigation to only a few representative areas. Initial studies, therefore, included test pitting and hand auger-drill sampling at two sites n Grant County and one site in Lafayette County to determine whether further extensive sampling in that area was warranted. Results indicated that certain portions of the area contained substantial amounts of lead and, zinc; accordingly, more detailed sampling was undertaken, and the results will be described in a later report. Another phase of the general investigation was drilling and test pitting at the Nigger Jim Lafayette County. This 10 the third of the series and summarizes the work on the White property to develop the western extension of the Big Dick ere body, where four churn-drill holes totaling 679 feet were drilled. Inclusion of the White property in the study was justified because old reports indicated (1) production of ore from mines in the vicinity disclosed a high ratio of lead to zinc, (2) ore was present in the west heading of the Big Dick mine when it closed, and the attitude of the Big Dick ore body was such that a vertical hole would encounter ore that might be present.

Jan 1, 1950

By Allen D. Look, J. Howard Bird

"INTRODUCTION The Phelps-Dodge Corp. New Cornelia Branch open-pit copper mine operated without a fatality in the drilling and blasting department from December 13, 1937, to April 1, 1947, and continuing.Between the dates named the explosives crews had a total of 746,520 man-hours of exposure and handled 12,000 tons of explosives, over 770,000 detonators, 2,300,000 feet of fuse, and 7,700,000 feet of Primacord in loading holes to break 116,780,000 tons of material.It is the purpose of this paper to record the procautions taken to insure safe handling of explosives at this operation where safety is definitely a matter of forethought rather than chance.GENERAL INFORMATIONThe New Cornelia Branch open-pit mine operates on a large, low-grade, disseminated-copper deposit about one-half mile south of Ajo, Ariz. The pit is approximately oval; the ore body being some 4,800 feet long and 2,750 feet wide. Ore is mined with electric shovels loading into railroad cars. All benches in- the pit are 40 feet in height except two, which are 60 feet high.The New Cornelia ore body differs from most porphyry-copper deposits in being hard and siliceous. In common with the other low-grade porphyry-copper deposits, continued operation is possible only with economical handling of large tonnages. This has necessitated a great deal of study in the evolution of a safe and efficient method of handling the large quantities of explosives needed in breaking this hard-rock material."

Feb 1, 1948

By C. L. Wright

In 1904 the Government began a series of fuel-testing investiga- tions at its fuel-testing plant at St. Louis, Mo. These investigations, which were placed under the supervision of the United States Geo- logical Survey, included chemical analyses, steaming tests, gas- producer tests, briquetting tests, coking tests, and washing tests of samples collected from the various coal fields of the country. The specific purpose of the investigations was to analyze and test the coals and lignites in the United States, in order to deternime their fuel values and the most efficient methods of utilizing them for different purposes. Part of the fuel-testing plant, including the briquetting equipment, was moved to Norfolk, Va., in 1907, and the fuel-testing investiga- tions were made one of the divisions of the technologic branch of the Geological Survey. In 1908, after the close of the Jamestown Exposition, most of the fuel-testing equipment was removed to its present location at the Pittsburgh experiment station, Fortieth and Butler Streets, Pittsburgh, Pa. In 1910, an act of Congress, effective July 1, established the Bureau of Mines in the Department of the Interior and authorized the transfer to this bureau of the fuel-testing investigations that had been carried on by the technologic branch. Bulletins presenting the results of various inquiries and investiga- tions relating to briquetting have been published by the Geological Survey and the Bureau of Mines. As the supply of some of these bulletins is exhausted, the Bureau of Mines has decided, instead of reprinting them, to publish the more important facts they contain

Jan 1, 1913

By R. V. Ramani, V. T. Burgos, J. A. McClay

Summary Cost models have, long been confined to the accumulation and analysis of static-data.. While historical and time study data are valuable for control of existing operations, for new systems and equipment, and for projections, they need to be adjusted or modified. The availability of computer-oriented systems simulators provide yet another method for costing these systems and equipment. This investigation has introduced a concept whereby continuous, variable data can be assimilated and analyzed through the combination of an economic analysis model, which includes a direct costing capability, with a systems simulator. This tandem operation permits increased flexibility and greater atten¬tion to detail in the evaluation of mining systems. The direct costing process is carried throughout the majority of the model operations. Labor and capital costs may be computed directly, even in the absence of the systems simulator, while operating costs re¬quire input parameters, at present, from the subsystems of the Master Design Simulator. Since the costs computed are based on the perfor¬mance of each individual machine unit, the model may be used to evaluate equipment compatibility, system interaction at the mining face, and the effect of system elements on total mining costs. Additional applications of the cost model include the following: 1. Complete mining systems may be evaluated, over their economic life, to determine the feasibility of a profitable operation. 2. Costs associated with mining various segments of the coal deposit may be computed as a guide to planning the mine layout and scheduling the sequence of operations or acquisition of new

Jan 1, 1975

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

A. 3 Program Description The computer program developed to simulate events in the case of fire in the mine is described in this section The description is divided into three parts. 1. Program Capabilities This part summarizes what inputs can be changed, what outputs can be obtained and demonstrates program flexibility through suggested uses.

Jan 1, 1976

By Alla D. Mah

The heat of combustion of TaC0.996 was determined by oxygen bomb calorimetry to be -302.8 ±0.4 kcal/mole. The corresponding heat of formation of TaC0.996 is -35.4 ±0.5 kcal/mole, and the calculated heat of formation of TaC1.00 is -35.5 ±0.5 kcal/mole.

Jan 1, 1965

By Wilbert J. Huff

For the past 8 years the technical studies conducted by. the Explo- sives Division of this Bureau have been summarized in a series of annual reports.3 This report deals with activities from July 1, 1942, to June 30; 1943. Specific problems have been in immediate charge of section or unit leaders, to whom credit is given.

Feb 1, 1944

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

B 2 Program Use Instructions necessary to execute the program, after the card deck has been prepared, are summarized in the following. B 2. 1 Input Data Format Input data is supplied to the program in two ways a. By data cards that are read in after program compilation. b. By data specifications that are included within the program.

Jan 1, 1976

By H. C. Ko

As part of the Bureau of Mines effort to provide thermodynamic data for the advancement of mineral technology, the standard enthalpies of formation for ZnO?2ZnSO4 and COS04-6H20 were determined by HC1 acid solution calorimetry. The values are -550.31 ±0.28 and -641.33 ±0.15 kcal/mot, respectively.

Jan 1, 1982

By D. Harrington

"A tabulation is printed below showing the accident record of the thirty-two mines of the Anaconda Copper Mining Co., in Montana, for the years 1915, 1916, 1917, 1918, 1919 and 1920, with summation for the six years. The table gives the number of shifts worked by each mine with the serious plus fatal accident rate for each 10,000 shifts worked.It is seen that in a total of 16,460,767.5 shifts worked by employees of the company's mines during this six-year period, there were only 2,005 serious and fatal accidents and of these, 200 were fatalities, leaving 1,805 serious accidents (a serious accident being one in which 14 or more days' time are lost). This is at a rate of 9,120 shifts per serious accident and at a rate of 82,304 shifts per fatality. Hence, if 300 days be adopted as a year's work, there would be one fatality per 274.3 years of work in these mines and one serious accident for every 30.4 years work.According to Bureau of Mines Technical Paper 286, (Metal-mine accidents in U. S. in 1919, by W. W4 Adams), during the years 1916, 1917, 1918, and 1919, the metal mines of the United States worked a total of 210,548,640 shifts and had 39,705 serious accidents. During the same years, according to the following tabulation, the mines of the above-mentioned company worked 11,958,978 shifts and had a serious accident rate of 0.995 accidents per 10,000 shifts worked. If the metal mines of the United States, working these 210,548,640 shifts, had this company's serious accident rate of 0.995 serious accidents per 10,000 shifts, the total number of serious accidents would have been only 21,000 or the country's metal-mine serious accidents would have been reduced nearly one-half, and there would be 18,705 fewer serious accidents than actually occurred."

Jun 10, 1921

By George D. Dub, FREDERICK G. MOSES

The Bureau of Mines, in connection with the investigations of war minerals it conducted, examined the graphite deposits of this country, studied the methods of mining and preparation used, and sought to devise more efficient methods for the preparation of do- mestic graphite, and to standardize the quality of the product. The graphite investigations covered three general phases, as follows: 1. An examination of the deposits in Alabama and other States, and a survey of the methods of mining and preparation used. In this connection methods of sampling and analysis were noted and ex- periments made to determine a standard method of sampling and a rapid but accurate method of analysis. 2. Experimental work on the concentration and refining of domes- tic crucible graphite to improve the quality of the product and to lessen waste. 3. Experimental work in crucible manufacture to determine the properties of domestic flake and the maximum proportions that might be used without impairing the quality of the crucibles. This work was accompanied by photomicrographic study of crucible structure. In this bulletin are presented the results obtained in the first two phases of the work outlined above. The bulletin is in two parts. The first part describes the methods of mining and milling used, suggests a standard method of sampling finished graphite, and de- scribes a rapid and convenient method of analysis developed at the Pittsburgh station of the Bureau of Mines, to which had been as- signed the analytical and microscopic work. The second part describes experiments on the concentration and milling of graphite, which were made at the Salt Lake City, Utah, station. As soon as the reports incorporated in this bulletin were ready, mimeograph copies were distributed to those persons most interested in order to make the results immediately available. The experimental work on crucible manufacture, assigned to the Columbus, Ohio, station, yielded results which were made known to the industry. Á report on this work will be published later as a separate bulletin.

Jan 1, 1920

By James Westfield, S H. Ash

Because of the increasing shortage of fuel in the United States, especially of residential fuel in the Eastern and New England States, it was essential that the maximum production of anthracite be obtained to help win the war and to prevent human distress. The nine railroads that depend on the anthracite region for a substantial portion of their business were not congested unduly with other traffic, because the region was not participating in industrial activities to the same degree as in many other sections of the United States; consequently, transportation of anthracite to the New England States, New York, New Jersey, and eastern Pennsylvania over a shorter rail haul than for any other fuel was desirable. The prevention of floods that would cause a loss of anthracite production was important to the war program. Every shutdown deprives the northeastern section of the United States of anthracite that is needed badly. Failure to prevent inundation of anthracite mines halts production, endangers the lives of workmen, damages, sometimes beyond repair, vital underground equipment, and threatens the permanent loss of a large portion of the Nation’s anthracite reserves. Funds were made available to the Department of the Interior, Bureau of Mines, for the fiscal year ended June 30, 1945, through a supplemental appropriation for anthracite investigations, one of which was to conduct inquiries and scientific and technologic investigations that have a bearing on the anthracite mine-flood problem. As part of the investigation, the Bureau proposed to obtain the cooperation of the anthracite-mining companies and the State in effecting a program to prevent the inundation of mines in the anthracite region. No large engineering projects were undertaken by the Bureau during the fiscal year ended June 30, 1945, on the anthracite mine-flood problem. Small projects were chosen that could be completed within 1 year to prevent loss of anthracite production at a critical time. It was believed that such projects would lessen the chance that flood water would inundate active mine workings.

Mar 1, 1946