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Application of Programmable Logic Controller For Gases Monitoring in Underground Coal Mines

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Application of Programmable Logic Controller For Gases Monitoring in Underground Coal Mines

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Application of Programmable Logic Controller for Gases Monitoring in


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IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.3, No.3, June 2013

Application of Programmable Logic Controller for


Gases Monitoring in Underground Coal Mines
R. Mandal*, A. Kumar, T. M. G. Kingson, RK. Pd. Verma A. Kumar, S. Dutta, S. K. Chaulya and G. M. Prasad

CSIR-Central Institute of Mining and Fuel Research, Barwa Road, Dhanbad, India.
*Corresponding Author’s Email: [email protected]

Abstract— Nowadays mining industry is experiencing many Network (ANN), Distributed Control System (DCS), Human
changes. One of the many developments, looming on the horizon, Machine Interface (HMI), and Programmable Automation
having potential to change the fundamental nature of mining as it Controller (PAC). Whereas mechanization provides human
is practiced today: automation. Automation in mining industry operators with machinery to assist them with the muscular
would be useful for safety and large production. It is based on requirements of work, automation greatly decreases the need of
geographic location of operation, so naturally use of automation human sensory and mental requirements as well [3].
is to achieve operating goals such as maintaining required
digging profiles, avoidance of hazards, obstacle, etc. Mining In a traditional industrial control system, all control
industry continuously strive to find better ways to increase devices are wired directly to each other according to how the
output, improve quality and uphold the highest safety standards system is supposed to operate while using PLC system, wiring
while decreasing cost and protecting the environment. This paper between devices is reduced. Thus, instead of being wired
presents applications of programmable logic controller in directly to each other, all equipment is wired to PLC. Then, the
underground coal mines for key activities of automatic mining control program inside PLC provides the “wiring” connection
operations and will focus on conveyor belt system, gas monitoring between the devices. The control program is the computer
and control with help of different gas sensors, for automatic program stored in the PLC memory that tells the PLC what is
control and cutoff power supply of a particular area in going on in the system [4]. This paper presents applications of
underground mine when concentration of flammable gas exceeds
PLC in mines for automatic mining operations. Applications of
more than the permissible limit.
PLC in open cast mines industry are mine blasting, excavation,
Keywords- Automation, PLC, Sensors, Underground Mine loading and transportation etc. For underground mines,
gases. applications of PLC will be suitable for controlling conveyor
belt system, gas monitoring with the help of different gas
sensors, ventilation and automatic cutoff power supply of
I. INTRODUCTION certain areas in an underground mine when concentration of
In the past, systems were controlled manually. Modern day flammable gas exceeds permissible limit.
machineries consist of electrical, mechanical, electronics and
instrumentation parts. They use electricity, hydraulic, II. MINING METHODS
pneumatic and electronics controller for control and monitoring
operations [1]. Therefore, all of these have been mixed as a Coal is mined by two methods:
branch, named “Mechatronics”. Automation is a part of A. Surface or opencast mining
mechatronics. Automation means self-moving. It is derived B. Underground or deep mining
from two Greek words Auto and Matos, Auto means itself and The choice of mining method is determined by the geology
Matos means moving. Therefore, automation may be defined of coal deposits i.e. depending on the depth of the seam or
as the use of control systems and information technologies to seam to be extracted. Underground mining currently accounts
reduce the need of human involvement in the production of for a bigger share of world coal production than opencast.
goods and services, i.e. automation is the technology by which Approximately 60% of world coal production is produced from
a process or procedure is accomplished to minimize human underground mines. India is the third largest coal producing
assistance and error. It is implemented using a program (a set countries [5, 6] but in India surface mining accounts for about
of instructions) combined with control system that execute the 90% whereas only 10% comes from underground mining.
instructions. To automate the process, power is required both to
drive the process itself and operate the control system [2]. A. Surface Mining
Automation has successfully been used in the field of Surface mining: - It is also known as opencast or open cut
automotive, aerospace, power, steel and process industries by mining. Surface mining is only economically feasible when
providing maximum flexibility at minimal cost while the coal seam is near the surface. The exposed coal is drilled
maintaining benefits of increased quality, safety and control. and drill holes are filled with explosives for blasting. Then
Automation plays an increasingly important role in economy overburden is removed with large draglines, shovels and trucks
and daily experience. Some of the widely used automation or bucket-wheels and conveyors to the coal preparation facility.
tools are programmable logic controller (PLC), Supervisory This method recovers a higher proportion of coal deposit than
Control and Data Acquisition (SCADA), Artificial Neural underground mining as all coal seams are exploited 90% or

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Vol.3, No.3, June 2013
more of the coal can be recovered. Large opencast mines can of mechanised roof bolting using hydraulic bolts for difficult
cover an area of many square kilometers and use very large roof are new technology absorptions in Indian Underground
pieces of equipment, including: Coal Mining. Mechanized Long wall mining (long wall
• Draglines, which remove the overburden powered support) has also been introduced in a limited scale
which yields higher output with high percentage recovery (70-
• Power shovels 80%) [21]. Mining industry continuously strive to find better
ways to increase output, improve quality and uphold the
• Large trucks, dumpers
highest safety standards while decreasing cost and protecting
• Bucket wheel excavators the environment, which is possible by implementing PLC
system and help for atomization.
• Conveyors
IV. PROGRAMMING LOGIC CONTROLLER
The coal is then loaded on to large trucks or conveyors for
transport to either the coal preparation plant or directs to where Earlier, human operator used to control a system, which
it is to be used [5]. was later substituted by electrical relays. These relays allow
power to be switched on and off without a mechanical switch.
B. Underground Mining It is common to use relays to make simple logical control
decisions. The development of low cost computer has brought
There are two main methods of underground mining:-
the most recent revolution, the Programmable Logic
1. Room and Pillar Mining Controllers (PLCs). The advent of PLC began in 1970s, and
has become the most common choice for manufacturing
Room and pillar mining is generally used at shallow depths, controls [9]. A PLC is programmed to control the operation of
where the geology of the coal seam is too complex for longwall plant/mines. The block diagram of PLC shows in figure 1. PLC
mining. In room and pillar mining, coal deposits are mined by is a digital industrial computer. It can be defined as a digital
cutting a network of rooms into the coal seam and leaving electronic device that uses a programmable memory to store
behind pillars of coal to support the roof of the mine. Up to instructions and to implement specific functions, such as logic,
60% of the coal can be recovered, with the remaining 40% sequencing, timing, counting and arithmetic to control, through
forming pillars which support the mined out rooms. These digital or analog input/output modules of various types of
pillars can be mined as the final stage in the extraction of the machines or processes. Modern control systems still include
section [7]. relays but these are rarely used for logic. Relay is a simple
2. Longwall Mining device that uses magnetic field to control a switch. When a
voltage is applied to the input coil, the resulting current creates
Longwall mining comprises full extraction of coal from a a magnetic field. The magnetic field pulls a metal switch (or
section of the seam, or face using mechanical shearers. reed) towards it and the contacts touch, closing the switch.
Longwall mining is almost a continuous operation involving
the use of self advancing hydraulic roof supports, sophisticated
coal shearing machine and armored conveyor, paralleling the
coal face. Working under movable roof support, the shearing
machine cuts and spills coal and rides on conveyor, for
transport out of the mine. Longwall mining is a very efficient
coal producing technique. Its productivity potential is higher
than that of room and pillar mining, because longwall mining is
basically a continuous operation require less workers. Over
75% of coal in the deposit can be extracted from panels of coal
that can extend 3km through the coal seam. Almost all modern,
high-production mines use a retreat longwall method of mining
[5, 8].

III. STATUS OF COAL MINING INDUSTRY IN INDIA


Coal mining in the India is carried out by generally two
methods; opencast and underground. Opencast mining
contribute over 90% of total production whereas rest of the
production (about 10%) comes from underground mining [21].
These mines are mostly semi-mechanized. The machinery Figure 1. Block diagram of PLC
commonly deployed is drill machines, load-haul dumper The contact that closes when the coil is energized is called
(LHD), ventilation fans, pump for dewatering, haulage for normally open. The normally closed contacts touch when the
transport, etc. In underground mines, mass production input coil is not energized. Relays are normally drawn in
technology is used by introducing continuous miner. Modern schematic form using a circle to represent the input coil. The
roof- bolting technology with flexibolts up to 5 m length; output contacts are shown with two parallel lines. The term
smart bolting for cost reduction of roof support; introduction logic is used because the programming is primarily concerned

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IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.3, No.3, June 2013
with implementing logic and switching operations. The input • Programming software
devices (e.g. switches, sensors, gas sensors, limit switches,
inclinometers and push buttons etc.) and output devices (e.g. • Connector cable
motor relay, contactor etc.) being controlled are connected to
PLC, and then to the controller monitors and the inputs/outputs
according to the program stored in PLC by the operator to
control the machine or process. Originally PLCs were designed
as a replacement for hard-wired relay, timer, and counter logic
control system. PLCs have a great advantage that it is possible
to modify a control system without having to rewire the
connections to the input/output devices, the only requirement
being that an operator has to key in a different set of
instructions. The result is a flexible system, which can be used
to control systems, which vary quite widely in their nature and
complexity.
The soft wiring advantage provided by programmable
controllers is tremendous. In fact, it is one of the most
important features of PLCs. Softwiring makes changes in the
control system which is easy and cheap. If you want a device in Figure 2. Architecture of PLC
a PLC system to behave differently or to control a different
process element, all you have to do is change the control The input and output modules are connections to the industrial
program. In a traditional system, all control devices are wired process that are to be controlled. Inputs to the controller are
directly to each other according to how the system is supposed signals from limit switches, pushbuttons, sensors, and other
to operate, making any changes would involve rewiring on/off devices. In addition, larger PLCs are capable of
between the devices which is a costly and time-consuming accepting signals from analog devices of the type modeled.
endeavor. PLC system eases maintenance and troubleshooting. Output from the controller is on/off signals to operate motors,
In PLCs the relations between inputs and outputs are valves, and other devices required to actuate the process. The
determined by user program. By using advanced programming processor is the central processing unit (CPU) of the
technologies it is much easier to implement complex control programmable controller [10]. The processor of PLC is very
algorithms than in any hard-wired solutions. The significant similar to microprocessor/microcontroller and those used in
advantages of using a PLC over conventional relays, timers, personal computers and other data-processing equipment.
counters, and other hardware elements are as follows: Thus, PLC consists of central processing unit (CPU) similar to
computer, memory, and input/output modules. However, a
• Programming the PLC is easier than wiring a relay logic control system has no memory and does not consider any
control panel and is often scrapped during rewiring. previous values of the input signals in determining the output
signal. The CPU controls and processes all the operations
• It has easy maintenance and higher reliability. within the PLC. It is supplied with a frequency and a clock.
• PLC can be connected to the plant computer systems Frequency determines the operating speed of PLC and provides
easily. timing and synchronization for all elements in the system. A
bus system carries information and data to and from the CPU,
• PLCs can be used with robots to perform hazardous memory and input/output units. PLC is designed for multiple
industrial operations, making it possible for humans to input and output arrangements extendable to further required
perform more intellectually demanding functions. modules. There are several memory elements: a system ROM
to give permanent storage for the operating system and fixed
• PLC is low cost automation system.
data, RAM for the user’s program, and temporary buffer stores
for the input/output channels. The automation process also has
A. Basic structure of PLC system flexibilities in programming and control techniques [11]. The
PLC contains mainly two parts- hardware and software. A PLC is designed to provide flexibility in control based
schematic architecture of PLC shows in figure 2. The basic programming, executing logic instruction and realization of
components of the PLC are as follows: complex control algorithms. PLC allow for shorter installation
time and faster commissioning through programming rather
• Input module than wiring [12]. In order to create or change a program, the
• Output module following items are needed:
• Processor • PLC
• Memory • Programming Device
• Power supply • Programming Software
• Programming device • Connecting Cable

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IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.3, No.3, June 2013
The basic operation of PLC system shows in figure 3. take place when the two devices speak the same language or
protocol.

B. PLC in mining automation technology


Nowadays the mining environment has changed
dramatically; and has seen many new developments in
technology, automation, communications systems, and
computerized process control and worker safety monitoring
[13]. Automation works mechanically and controlled
electrically. PLC controls many electrical and mechanical
devices, such as sensors, gas sensors, relay, contactor, switches,
motors, hydraulic and pneumatic valves, solenoid valves etc. A
sensor can be defined as a device capable of converting energy
from one form into another. Sensor senses the desired physical
quantity and converts it into another energy form. The function
of a Safety System is to monitor and control conditions on a
machine or process that are hazardous in them or, if no action
were taken, may give rise to hazardous situations. The Safety
System runs in parallel with the Control System. The safety
system is often referred to as “safety control” while the PLC
Figure 3. Basic operation of PLC system
system controlling the devices that produce the end product is
often referred to as the “standard control” [14]. The major issue
The configuration of PLC with computer shows in figure 4. in the use of PLC in mining automation technology requires an
The program is created in a programming device and then understanding of various aspects of the selected area such as
transferred to the PLC. A software program is required in order geological site, hydrology, mining, drilling, exploration,
to tell the PLC what instructions it must follow. Programming electrical power supply and thermodynamics of the gasification
software is typically PLC specific. A software package for one reactions in the cavity are important parameters for successful
PLC, or one family of PLCs, such as the S7 family, would not operation. An exchange of knowledge between the various
be useful on other PLCs. PLC Software supports different fields is necessary. A Safety system is designed with PLC to
operating system like windows XP, vista, Win 7 etc. protect;
• People
• Environment
• Machinery

V. MINE GASES
Gases that appear in underground mines are highly toxic
and some are dangerously flammable when mixed with air.
Methane and CO are the most common dangerous gas found in
underground coal mines. Methane (CH4) is produced during
coalification (the process of coal formation). Only a fraction of
these remains trapped under pressure in the coal seam and
surrounding rock strata. This trapped methane is released
during the mining process when the coal seam is fractured.
Methane released in this fashion will escape into the mine area,
and will eventually escape into the atmosphere. Underground
coal mining releases more methane than surface or open-pit
Figure 4. Configuration of PLC with computer mining because of the higher gas content of deeper seams. The
amount of CH4 released during coal mining depends on a
PLC software is installed on a personal computer in a number of factors, the most important of which are coal rank,
similar manner to any other computer software. PLC programs coal seam depth, and method of mining [17]. Carbon monoxide
may be write in any of three forms, namely ladder logic (CO) is a deadly, colorless, odorless, poisonous gas. If the
diagram, statement list and function block diagram. Generally, methane gas from the coal seams is accumulated in
PLC is programmed using ladder logic method. The ladder underground spaces, a high risk of explosion may arise. So,
logic diagram writes in PLC software which is stored in a sensor must sense such accumulation and the ventilation
computer. Connector cables are required to transfer data from system should eradicate the gas when crosses the permissible
the programming device to the PLC. Communication can only limit using PLC system. Methane is measured in percentage by
volume between the ranges of 0-5%. CO concentration is

519
IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.3, No.3, June 2013
measured in parts per million (ppm). Gas sensors are used to which, for example, drives an actuator. Gas sensor determines
detect the presence of Carbon Monoxide gas at concentrations the concentration of gas accumulated in a protected area and
from 0-300 ppm measuring range (standard). In mines the transmits the information to an input module of PLC system.
permissible concentrations of CO gas is 0-50 ppm [18]. PLC Gas sensing system shows in the figure 5.
system performs monitoring, analyzing and controlling using
sensor capable to give both analog and digital output. Sensor
makes use of serial interface port to communicate with PLC
system.

VI. GAS MONITORING AND VENTILATION SYSTEM


Gas sensors monitor carbon monoxide, methane, carbon
dioxide, oxygen and differential pressure at ventilation splits
throughout the coal mine. In India many coal mines are closed
due to presence of hazardous gases (CO, CO2, CH4, SO2 etc.).
Thus, it is important to use PLCs for gas monitoring and
control of ventilation system in those mines for efficient
removal of gases and provide a safe working zone. There are
two kinds of Risk Zones, namely, Explosive Risk Zones (ERZ)
and Negligible Explosive Risk Zone (NERZ). These are
defined as:
• ERZ0 is “an underground mine, it is identified by a
risk assessment as likely to be, greater than 2%”. These Figure 5. Gas sensing system
areas are typically sealed off and inaccessible areas
with no ventilation. PLC consists of an analog input module that reads the 4 -
• ERZ1 is “an underground mine, where the general 20 mA signal from the sensor, a central processing unit, and an
body concentration of methane is known to range, or is analog output module that controls the required system
shown by a risk assessment as likely to range from variable. The current loop can handle large capacitive loads-
0.5% to 2%”. These areas are typically face or coal often found on hundreds-of-meters long communications paths
cutting areas and return airways. experienced in some industrial systems. The output of the
sensor element, representing gas concentration level is
• NERZ is “part of underground mine, where the general transmitted over the current loop. This simplified example
body concentration of methane is likely to be less than shows a single 4 - 20 mA sensor output connected to a single
0.5%”. These areas are typically fresh air intakes and channel input module and a single 0 - 10 V output [20]. Figure
referred to as Zone 2 in IECEx certified systems. 6 shows a typical gas monitoring and power cut-off system
through PLCs in running gaseous underground coal mines. All
• These boundaries are typically only valid while the gas sensors are connected to the input module of PLC and
mines ventilation system is operational. When no alarms, and actuator are connected to the output module of
ventilation is present the whole mine is considered to PLC. CH4 and CO gas are most commonly found hazardous
be an ERZ0. gas in underground mines.
In an underground coal mines, gas monitoring and
ventilation control system with different gas sensors are
installed at air outlets forming zone boundaries and provide
local visual indication:
• Healthy when the methane level is below 0.25%.
• Warning when the methane level is between 0.25% and
0.49%.
• Alarm when the methane level is above 0.49% [19].

A. Process Description
PLC takes real time decision depending upon the various
field level input signals from various gas sensors placed at
different critical points and sends decision to the output devices
after processing. A process variable, such as flow rate or gas
concentration in underground coal mines, is monitored via the
input module. The information is processed by the central Figure 6. Block diagram of automatic gas monitoring and
control unit; and relevant action is taken by the output module, power cut-off system

520
IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.3, No.3, June 2013
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controlling function. The PLC is designed to provide flexibility
in control based programming and executing logic instruction, AUTHORS PROFIL
realization of complex control algorithms. PLC allow for
shorter installation time and faster commissioning through Ranjeet Mandal completed P.G. Diploma (Industrial
programming rather than wiring. Automation), B. Tech in Electronics & Instrumentation
and currently working as a Project Assistant in CSIR-
CIMFR, Dhanbad.
ACKNOWLEDGMENT Resarch Area: Automation, underground coal gasification.
Authors are grateful to Dr. Amalendu Sinha, Director, [email protected] .
CSIR-Central Institute of Mining and Fuel Research, Dhanbad
for giving permission to publish the paper.
Mr. Anish Kumar, B.Tech. (ECE)
Junior Research Fellow
REFERENCES CSIR-CIMFR, Dhanbad
Research Area: Sensor, Wireless Sensor Network.
[1] S. K. Singh, D. Prasad, G. Agarwal, M. Parikh, P. Ramadhyani, J. S.
Parikh, A. Datta and S. Chatterjee, “PLC based industrial automation”, [email protected]
Electrical India, vol. 50, no. 6, June 2010.

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IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.3, No.3, June 2013
Mr. T M Giri Kingson, B.Tech. (AEI)
Project Fellow
CSIR-CIMFR, Dhanbad
Research Area: Sensor, WSN.
[email protected]

Mr. Abhishek Kumar, B.Tech. (EIE)


Project Fellow
Research Area: Sensor, Coal gasification.
[email protected]

Mr. Rajkumar Prasad Verma, B.Tech. (CSE)


Project Fellow
Research Area: WSN, Cloud Computing, Sensor.
[email protected]

Mr. Subhadip Dutta, B.Tech. (CSE)


Junior Research Fellow
CSIR-CIMFR, Dhanbad
Research Area: Algorithm, WSN.
[email protected]

Dr. Swades kumar Chaulya, B. Tech., M. Tech., Ph.D.


(IIT, BHU)
Scientist
CSIR-CIMFR
Research Area: Wireless Communication, Control
Monitoring Automation in Underground Mines.
[email protected]

Dr. Girendra Mohan Prasad, M.Sc., Ph.D. (ISM,


Dhanbad)
Sr. Principal Scientist
CSIR-CIMFR, Dhanbad
Research Area: Mine Instrumentation and Communication.
[email protected]

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