Lighted_lifeline_SOW_3-31-16.docx

NIOSH Lighted Lifeline Statement of Work March 31, 2016

Background and need: The authors of the report Improving Self-Escape from Underground Coal Mines, identified the need to empower miners to self-escape during a mine emergency (NRC, 2013). Numerous recommendations were put forth, including the need to accelerate wayfinding technology efforts that enhance situational awareness (SA) and self-escape (NRC, 2013). Currently, self-escape technologies include signage for marking escapeways and lifelines, but these technologies have major limitations as currently applied in mining.

Lifelines (Fig 1) are used for self-escape. They provide a sensory cue given they are fitted with directional cones that are felt with a gloved hand to guide miners in low-visibility smoke conditions. Lifelines can be difficult to find in the underground mining environment, so a lighted lifeline is desired to help miners find the lifeline in smoke conditions. NIOSH research will be conducted to determine the effectiveness of a lighted lifeline to help miners escape.

Figure 1. A conventional lifeline in a mine. (image from CAB Products website http://www.cabproducts.com/high-visibility-reflectors/).

NRC. (2013). Improving Self-Escape from Underground Coal Mines. Washington, D.C.: The National Academies Press.

The contract services will result in a field-worthy, lighted lifeline module and written report documenting the design and performance.

This contract will have these key stages:

The work of the key stages shall meet the following requirements

1. General requirements:

1.1. The vendor is responsible for providing a continuous lighted lifeline cable comprised of a clear thermosplastic extrusion incorporating electrical wires and a Corning® Fibrance™ Light-Diffusing Fiber. Each end of the lighted lifeline is terminated with a laser battery controller (LBC) (Fig. 2).

1.2. The vendor is responsible for providing a master LBC and a slave LBC (Fig.2).

1.3. The vendor is responsible for integrating the lighted lifeline cable with the master and slave LBCs (Fig. 2).

1.4. The lifeline cable (Fig 3.) is to be a clear, low haze thermoplastic co-extrusion cable containing three electrical conductors and a Fibrance optical fiber.

1.5. The lifeline cable span is the distance between two LBCs.

Figure 2. Layout for a single module of the lighted lifeline.

Figure 3. Lifeline cross section illustration (not to scale).

2. Detailed technical requirements

2.1. Ambient conditions:

2.1.1. Temperature range: 10○ to 55○C.

2.1.2. Resistance to moisture: Mine water pH level: this can range to a pH of 4 to alkaline, depending on geology. Some lines are dry and others dripped water from the roof.

2.1.3. Rock dust/spray adhesion – needs to be withstand rock dust (Sample provided):

2.2. Hardware

2.2.1. The lifeline cable must be solid core.

2.2.2. The lifeline cable strength shall be greater than or equal to 300 pounds.

2.2.3. A strain relief must be provided for the lifeline cables connected to any LBC and a strain relied is needed for the 120VAC cable that connects to the master LBC.

2.2.4. Lifeline length between a pair of laser battery controllers (LBCs) = 250 to 500 feet (300 foot is target).

2.2.5. A lifeline module (Fig 1) consists of a master and slave LBC connected by the lighted lifeline.

2.2.6. Lifeline modules can be connected in series for a total length capability up to 5,000 feet. The total length of 5000ft would require one Master LBC and about 16 slave LBCs.

2.2.7. There is only one master LBC and it is powered by a supply voltage of 120 Vac.

2.2.8. The master LBC charges all slave LBC’s.

2.2.9. The 120 Vac cable that supplies power to the master LBC shall be 15 feet long and the cable shall be three conductor, 14 AWG DJ (double jacketed) cable.

2.2.10. The lighted lifeline segment between LCBs is illuminated by lasers at each end of the segment which connect to a LCB.

2.2.11. The 120Vac twin wire conductor coming from the master LBC is used to trickle charge all LCB batteries.

2.2.12. A ground wire shall be included which can serve as a stress member.

2.2.13. Each LCB shall be grounded.

2.2.14. 120VAC of the lighted life line must be fused for short circuit protection. See Appendix A for short-circuit calculation guidance.

2.2.15. Conductors shall have 14 AWG braided conductors sufficient to support current draw and line losses to enable a total length capability up to 5,000 ft.

2.2.16. The lifeline diameter shall be ≤ 0.25 inches.

2.2.17. Cross section – solid, circular where passing through packing gland of the LBC explosion-proof enclosure.

2.2.18. Each LCB must be housed in a MSHA-certified 30 CFR 57 explosion-proof enclosure. Appendix B lists manufactures of MSHA certified enclosures.

2.2.19. Lifeline flammability: Acceptable flame resistance of a product will be determined by MSHA in accordance with both of the following flame test procedures:

2.2.19.1. “2G” test: ASTP5007 - MSHA’s Standard Flame Test Procedure for: Hose Conduit, Fire Suppression Hose Cover, Fire Hose Liner and Other Materials; Title 30, Code of Federal Regulations, Part 18, Section 18.65

2.2.19.2. Test for flame resistance of signaling cables. Title 30, Code of Federal Regulations, Part 18, Section 7.480

2.2.20. Laser connector diameters should be less than 0.25 inches diameter.

2.3. Functionality Requirements

2.3.1. Normal mode (armed & ready): System flashes (pilot) at very low frequency (0.1s every 30 s) to confirm viability. This function is provided during normal production operations in a mine.

2.3.2. Battery Backup: Once an emergency is detected (loss of electrical power 120 Vac going to the master LCB), all power is shut down activating the lighted lifeline. Power is then supplied by the battery backup of each LCB thus the lighted lifeline is in emergency mode (normal alarm):

2.3.3. Loss of electrical continuity The lighted lifeline will transition to a non-powered state (the lasers are shut off). It is assumed that loss of electrical continuity is caused by a severed lifeline. The lasers are shut off to prevent a potential eye hazard from a severed cable.

2.3.4. Emergency mode (normal alarm): Once activated by a loss of supply voltage to the master LCB, all lasers pulse on/off at four hertz, 50% duty cycle (normal life). The emergency mode occurs during a mine disaster at which time all electrical power in the mine is deactivated. No electrical current is to flow

2.3.5. Emergency mode (normal alarm): Battery backup must provide sufficient power to operate the lighted lifeline for 96 hours at 50% duty.

2.3.5.1. After 48 hours laser source pulses on/off at four hertz, 25% duty cycle (extending life).

2.3.5.2. After 72 hours laser source pulses on/off at four hertz, 12.5% duty cycle (extending life)

2.4. Laser Requirements

2.4.1. Max Laser Power: The maximum power for all laser sources, pulsed at 4 hertz, is 150 mw as determined by using IEC 60079-28/Ed2: Explosive atmospheres – Part 28: Protection of equipment and transmission systems using optical radiation. Any pulses greater than 0.2 hertz are considered to be a continuous wave in this standard.

2.4.2. Green Lasers: 80mw, approximately 520nm. The green lasers must be used for the lighted lifeline module depicted by figure 2.

2.4.3. Red-orange lasers: 80 mw, approximately 635nm. These lasers must be able to illuminate the lighted lifeline in place of the green lasers. The purpose is to conduct a comparison to the green lighted lifeline.

2.4.4. Blue lasers: 80 mw, approximately 445nm. These lasers must be able to illuminate the lighted lifeline in place of the green lasers. The purpose is to conduct a comparison to the green lighted lifeline.

2.5. Photometric requirements:

2.5.1. Minimum Luminance = 89 cd/m2 - comparable to illuminated exit signs (14 CFR 23.811-23.813).

2.5.2. Uniformity ratio< 4:1 If min Luminance = 89cd/m2, this corresponds to max luminance < 356 cd/m2

2.6. Regulatory requirements

2.6.1. The lifeline is designed in accordance with 30 CFR 75.381 and 30 CFR 75.380 with the goal of seeking regulatory approval by Mine Health and Safety Administration (MSHA) ASAP 5001 “Application Procedures for Acceptance of Flame-Resistant Solid Products Taken into Mines”

2.6.2. The vendor will not submit the lighted lifeline to the Mine Safety and Health Administration (MSHA) for approval.

2.6.3. During normal mode operation, the lighted lifeline will be considered by MSHA as an electrical or signal cable per MSHA document ASP 5015 ver. 2010-11-01.

2.6.3.1. Electric cables are defined as an assembly of one or more conductors of #14AWG or larger, and having a voltage exceeding 50 volts.

2.6.3.2. Signal cables are defined as an assembly of one or more conductors of #14AWG or smaller or having a voltage less than 50 volts.

2.6.4. The system must comply with U.S. and European requirements for laser system safety.

2.6.5. The lifeline shall be permanently marked in black text at least 0.25 in. high “# 14/3 AWG 120Vac NIOSH Lighted Life Line ver.1”. The markings shall appear every three feet.

3. Progress Reporting Requirements: The contractor will provide a progress report at the end of stage 1 and stage 2. The progress reports will include a problems encountered or anticipated that would affect the outcome of the research, the schedule, or the budget.

4. Written final report requirements: The written final report shall document the lighted lifeline design and at a minimum include the following:

4.1. Power consumption and current level for each LCB

4.2. Laser pulse duration, pulse timing, pulse length, and CW laser power

4.3. Measurement of luminance in cd/m2 as a function of lifeline distance between LCBs.

4.4. Backup battery life test results once an emergency is initiated.

5. Deliverables

5.1. A written progress report at the completion of stage 1. Due 9 weeks ARO.

5.2. A written progress report at the completion of stage 2. Due 12 weeks ARO.

5.3. Three hundred feet of lighted lifeline cable (Fig 3) without the LBCs. Due 12 weeks ARO

5.4. Two lasers each as defined by sections 2.4.3 and 2.4.4. Due 12 weeks ARO

5.5. A fully functional field-worthy, green lighted lifeline module (Fig. 2) comprised of a master LBC, slave LBC, and 300 ft. of lifeline cable. Due 14 weeks ARO

5.6. Written final report verifying that the requirements have been met or exceeded. (Word file preferred). Due 16 weeks ARO. The written final report must include the following system documentation also provided as electronic files. The report should be in WORD file format, 2D CAD files should be in DXF or DWG formats, and 3D CAD files should be in STEP or IGES format. Due 16 weeks ARO

5.6.1. Bill of materials

5.6.2. Schematic diagrams

5.6.3. System drawings

5.6.4. Instructions

6. Proposal Technical Evaluation Factors

6.1. Demonstrated understanding of the contract objectives, underlying issues, scope of work, and the detailed requirements as evidenced by the completeness and soundness of the approach presented in the proposal. (20 points)

6.2. Qualifications, skills, and experience of project personnel in the areas of: battery-backup design; custom design; mechanical, optical, and electrical engineering; laser safety compliance; laser optical measurement; laser module/controller design; laser applications for harsh, industrial applications. (30 points)

6.3. Demonstrated capability in completing government contracts of this magnitude and scope in a timely and successful manner. (30 points)

Appendix A: Short-circuit calculation guidance.

For a 5000ft long lighted lifeline, the total length should be 10,000 ft. ( 5000 ft. from and back to master LCB). Kb =.0.70.

Appendix B: Manufacturers of MSHA Certified Explosion-proof Enclosures Joy Mining Machinery Attn: Dave Thomas P.O. Box 791 120 Liberty St.

Franklin, PA 16323

(814) 432-1592 Mining Controls, Incorporated Attn: Larry Rowley P.O. Box 1141 Beckley, WV 25801

(304) 252-6243

SMC Electrical Products Attn: Bill Blankenship P.O. Box 880 Barboursville, WV 25504

(304) 736-8933 Long-Airdox Company Attn: David Corns P.O. Box 1231 4041 Wurno Rd.

Pulaski, VA 24134

(540) 994-3782

Line Power Manufacturing, Incorporated Attn: Jim Martin 329 William St.

Bristol, VA 24203

(540) 466-8200 Eimco Coal Machinery, Incorporated Attn: Gary Raulerson P.O. Box 1100 Route 52 North Bluefield, WV 24701

(304) 324-3541

K H Controls Attn: Brett Yeager RD #2, Box 343B

(724) 459-7474 American Electric Attn: Parry Dacal P.O. box 710 Beckley, WV 25801

(304) 255-7438

This is not all inclusive listing and is not intended to be an endorsement or promotion of any companies listed. These companies are the ones that MSHA deals with most often.

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