Published in the May 2008 Coal USA Magazine

Phoenix First Response recently took the step to further these endeavors by opening a state-of-the-art gas laboratory and full-service gas chromatograph sales center. According to the company, it is the only organization in America that provides coal-specific gas chromatography expertise.

“Phoenix is mainly known for our jet-engine gas inertization system,” said Phoenix First Response president David Hussey. “But we are constantly working to build a one-phone-call resource of gas, safety and rescue related services.

“Our team has been involved with almost every thermal event in US mining, and several internationally, over the last 20-plus years, so establishing a full-service gas laboratory was the next logical step to best serve the industry.”

Company manager Ian Houlison concurred. “Regulatory changes for ventilation have increased the focus on gas monitoring in the past few years, and the pressure on mines for reliable results.”

The recently published 30 CFR Part 75 final rule mandates extensive requirements for gas monitoring and inerting around sealed areas. All seals must be sampled and monitored until cured.

Areas behind any new or previously built seal that cannot bear at least 120psi of overpressure must be continually monitored for explosive gas concentrations. Baseline gas profiles for these seals must also be established with daily sampling for 14 days. Accurate sample analysis is essential to determine if inerting or evacuations need to be implemented in order to satisfy regulatory procedures.

Mines seeking more efficient means to meet the recent regulations have turned to Phoenix, which has offices in Pittsburgh, Pennsylvania and near Grand Junction, Colorado, for both temporary and ongoing assistance. Some prefer to outsource the entire monitoring and analysis process, while others prefer to purchase a gas chromatograph (GC) system to use in-house with optional support services from Phoenix.

The Phoenix laboratory’s independent results and expert consulting allures customers concerned with more stringent scrutiny of ventilation plans. The lab follows internationally recognized standards.

Services include routine and emergency sampling, monitoring and analysis using Varian micro gas chromatographs, which were developed from NASA technology. SmartGas software is utilized in conjunction with the Varian GC to facilitate the analysis process.

The program was created in Australia specifically for coal gas analysis, and has been honed over 20 years of use with Varian machines. Generalized gas chromatography software and equipment can be used for mining applications, although Houlison maintains that the combination of the Varian equipment and SmartGas software “far exceeds” any other set-up in accuracy, speed and repeatable results.

The Phoenix GC system enables detection of hydrogen, methane, carbon monoxide, oxygen, nitrogen and other higher hydrocarbons at concentrations as low as one part per million. The laboratory’s customized services range from one-time analysis to ongoing turnkey packages, to consultation to emergency event support.

Mining operations traditionally perform gas monitoring in-house. For some operations, continuing to do so will make more sense to satisfy new regulations.

Recognizing this, Phoenix sells and supports the same Varian GCs and SmartGas software used in its laboratory to companies wishing to keep all or partial gas analysis efforts in-house.

As the exclusive distributor of both technologies in the US, Phoenix provides ongoing customer service for these systems including installation and personnel training. The Phoenix system is the only GC set-up allowing remote calibration and servicing via the internet.

“One unique and strong advantage that we offer over competing systems is a dedicated, 24-hour support line,” said Hussey. He cites the organization’s unique safety-net mechanisms as “must-haves” for an industry where the saying “time is money” is not just a cliché

Phoenix’s laboratory services include support to customers purchasing GC systems. Loaner machines are available to significantly decrease onsite down time in the event of in-house equipment malfunction. The laboratory also offers verification of in-house results, analysis of results for improved ventilation planning, and other consultation.

Houlison says that maintaining the accuracy of gas chromatograph equipment is difficult, and it must be used frequently in order to do so – a major reason Phoenix cites to enlist the assistance of a full-service laboratory or a distributor that provides intensive equipment support for purchased systems, whether that be Phoenix or other companies.

The most recent federal register also requires that “certified persons be trained in sampling procedures”; these include sampling technique, equipment calibration, site-specific information, recording procedures, and general mine gas information. Phoenix offers this hands-on training as a solution for mines facing a shortage of trainers and gas technicians in the industry-wide crunch for skilled labor.

“The bottom line is that we want to assist the industry in effectively utilizing gas monitoring to meet regulations, and improve safety and efficiency,” said Houlison. “We can help each mine develop a highly efficient approach, whether that means commissioning us to perform a gas monitoring program or collaborating to build a strong in-house plan.”

New standards leave most mines with “outdated” seals and gas issues which they must address. Due to the expense of continual inerting, some mines may choose to update seals instead. However, Phoenix does not expect that to largely impact demand for the organization’s services.

“Phoenix offers an integrated approach to issues related to gas monitoring. We have a full panel of complementary expertise,” said Houlison, who emphasized benefits of intensified monitoring not only behind seals, but also of unsealed gobs, return airways and other areas. By establishing baseline gas levels and routinely gathering further readings, much can be learned about a mine’s “typical” behavior, he said.

This knowledge can assist in the prediction and prevention of potentially minor to severe thermal events. By increasing the monitoring and scrutiny of abnormal gas levels, mine management can more accurately and quickly respond to potential problems.

In the case of an event, these records enable more effective management. Overall, safety of those underground is greatly improved. Production benefits in a range of ways, including increased planning capacity, as well as by preventing evacuations caused by uncertainty of underground conditions. “Gas analysis is beneficial and cost-effective no matter what the regulations require,” Houlison said.

Complementary Phoenix services include emergency management and consultation; post-event investigation; the jet engine inerting system; a nitrogen generation partnership with Weatherford; seals and stoppings; and downhole drilling and cameras.