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TUBE BUNDLE SYSTEM DESIGN Gas Monitoring
TUBE BUNDLE SYSTEM DESIGN Gas Monitoring
Company Overview
Product Overview
Project Design
Project Structure
Components
Competitive Advantage
Tube Integrity Testing
Additional Products
Operating Systems
Table of Contents
Delta Automation has been providing Gas Management Products and Services, On-site Electrical Labour and
Automation and Control Solutions to the coal mining industry since 1996. We have a strong commitment to safety
and to date are proud to be a 100% LTI free organisation.
Delta Automation’s experience in gas management, engineering, electrical services and control products is enhanced
by our development and manufacturing capabilities. This has allowed us to offer our clients complete solutions;
turning concepts into reality and producing a wide range of products with a focus on four key areas:
1. Improving mine safety through gas management innovation.
2. Improving communications in the underground mining environment.
3. Implementing professional methods to monitor and report on production performance.
4. Continuous safety improvements through innovation and collaboration.
Company Overview 23yrs
LTI
Free
Designed from the ground up to comply with -
AS 3000 & other relevant ASNZS Standards
NSW Coal Mine Regulations
Emerson analysers providing high accuracy, fast response and long term stability.
All major components mounted on front panel for ease of viewing.
Rotameters on all tubes to allow for flow balancing and monitoring of each individual tube.
Low volume flow path to allow for low purge time between samples
All electronic components suitably IP rated, are in an IP 65 enclosures or are installed in the
communications hut.
Supplied with high efficiency, high flow rate purge pumps to allow for high flow rates from the mine,
leading to lower time delay from samples points.
Tube Bundle Key Features
The System is set to measure standard mine gases, but also can be configured with a GC to detect and
record other gases such as
Hydrogen, Ethylene, Ethane, Acetylene
Standby sample and purge pumps supplied connected and ready to operate to allow for rapid recovery
time in the event of a pump failure
Ethernet connection to analyser to allow for remote access for high level remote diagnostics
System can be supplied with IP cameras to allow remote monitoring
Check valves fitted on each line to prevent air ingress back into the tubes
System was designed in consultation with experienced ventilation officers as well as DII personnel to
maximise functionality while ensuring compliance with standards.
Key Features Cont.
The system is made up from two separate buildings –
1. A naturally ventilated building housing the Emerson gas analyzer/s and instrumentation.
2. A demountable ‘communications shed’ housing communication and control equipment.
This ‘naturally ventilated’ design eliminates several hazards associated with conventional Tube Bundle System designs.
Tube Bundle Design
Gas Analyzer Shed
Communication Shed
Tube Bundle Design Cont…
The standard gas building is
manufactured from galvanised mesh and colourbond
sheeting to provide natural ventilation and security against unauthorized access,
whilst still ensuring the compliance with Australian and NSW Mines Department requirements.
Emerson X-Stream process gas analyzer is used to deliver high accuracy gas readings. The X-stream measures up to four components in various combinations, and its versatile design allows physical benches to be installed in their own compartment, separate from the electronics.
In addition to the X-Stream gas analyzer, an Emerson Gas Chromatograph can be installed to assist with monitoring of trace gases in the mine. Typically the GC would be setup to measure trace levels of hydrocarbons.
Tube Bundle Design Cont…
All control and monitoring components are
mounted on the front panel and include vacuum and sample
pump pressure transmitters with displays as well as a flow controller to ensure a regulated
flow of gas independent of tube resistance.
Tube Bundle Design Cont…
The calibration gas connection facilitates
easy calibration of the analyzer by simply a click of a button.
To monitor system stability test gas cylinders have been designed to be included within the sample
gas sequence.
Tube Bundle Design Cont…
Hazardous Area Classification
Prior to manufacture, the system design was assessed for hazardous zoning to determine the types of components which were to be used in the final design and their permitted locations .
Hazardous Area Classification
Tube Bundle Component Selection
Water Trap
Rotometer
Double Ferrule Fittings
Flame Arrestors
Pressure Transducer
Tube Bundle Structure
CORRUGATED IRON
GAS CYLINDERS
STEEL MESH
Tube Bundle Structure
FLEX IO ENCLOSURES
INCOMING TUBE BULKHEAD FITTINGS
VENTURI SOLENOID ENCLOSURE
SAMPLE PUMPS
VENTURI COMPRESSOR
LIGHTING
ANALYZER
PUMPS
Tube Bundle Structure
FLEX IO ENCLOSURES
VENTURI SOLENOID ENCLOSURE
INCOMING TUBE BULKHEAD FITTINGS
CALIBRATION GAS SOLENOID ENCLOSURE
GAS CYLINDERS
LIGHTING VENTURI COMPRESSOR
SAMPLE PUMPS
ANALYSER
PURGE PUMPS
Tube Bundle Structure
ROTAMETERS
WATER SENSORS
SAMPLE PUMPS
WATER TRAPS
PRESSURE TRANSDUCERS
FLOW CONTROLLER
The tube bundle system comes complete with SCADA/CITECT screens and is Safegas compatible.
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Human Machine Interface (HMI) Software
Safegas SCADA / Citect
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Bundled Emerson Software
The Delta Automation TBH system is designed from the ground up with compliance in mind.
Hazard elimination through design ingenuity.
Explosion protection components meet Australian Standards and Department of Industry and
Investment (DII NSW) requirements using IECEx, ANZEx and ISO certification schemes.
Local support including engineering and technical training.
Delta Automation are the only company able to offer a complete life of mine package
including automated integrity testing.
Competitive Advantage
The Delta Automation mobile integrity testing unit is designed to comply with Australian Standards AS2290.3 relating to monthly leak testing and sample tube integrity. The systems eliminates safety hazards and labour intensive testing associated with traditional coal mine testing practices.
Safe – Scheduled testing & reporting to comply with AS2290.3 regulations. Fast – Methodical step by step approach much faster than current manual
methods Efficient – Portable & all testing completed from the surface at a
convenient time. Convenient – No disruption to sampling. Failure point location mapped to
+/- 50mtrs. All data logged on SQL database. Cost Effective – Eliminates mine site manual labour, u/g transport
requirements, reduces troubleshooting & repair times
Additional TBH Support Mobile Tube Integrity Testing Unit
Additional TBH Support Mobile Tube Integrity Testing Unit Benefits
Task Mobile Integrity Testing
Unit
Traditional Mine Testing
Methods
Mine compliance with AS2290.3 Easy Difficult X
Mine site staff required 0 2+ X
Scheduling with U/G staff required No Yes X
U/G transport required No Yes X
Time consuming & labour intensive No Yes X
Safety hazards encountered No Yes X
Real time reporting Yes No X
Accurate leak detections Yes No X
Convenient Yes No X
Testing of tubes where end point access is difficult or
impossible (ie buried in goaf) Yes No X
Additional TBH Products
Deltamation supplies single and bundled LDPE tubing in a range of colours.
Anti-static tubing suitable for underground environments with reflective tape, colour coding and numbered label easy identification.
LDPE Tubing
Additional TBH Products
End of line filters
Gas Chromatograph
Self-draining water filter panels
Water trap panels
Flame arrestors
3, 6 and 12mth maintenance schedules
Ashton Mine Gas Drainage Plant – Yancoal Australia
Abel Mine – Yancoal Australia
Mandalong Mine - Centennial Coal
Wambo Mine – Peabody Energy
Chain Valley Colliery – LDO
Integra Colliery – Glencore
Operating Tube Bundle Systems
Delta Automation Pty Ltd
Phone: +61 (02) 4932 4700
E-mail: [email protected]
12/37 Shipley Drive,
Rutherford NSW 2320.
www.delta-automation.com.au
