Refuge Chamber

Introduction

• Specifically designed and manufactured in order to provide a safe

haven in the event of underground emergency to personnel working
in Mines, Tunnels and on TBM.

• WeWalter refuge chambers are made by strong steel continuously

welded in order to provide robustness (TOUGHNESS) to the structure,
equipped with lifting lugs to enable ease of transportation.
 1. INTENDED USE – THE REFUGE CHAMBER IS INTENDED FOR INSTALLATION IN
UNDERGROUND JOBSITES AND MINES. IT IS USED AS A SAFE HAVEN HOUSING WORKERS IN CASE OF
EMERGENCY, FOR A DEFINED NUMBER OF PERSONS AND A DEFINED TIME OF AUTONOMY.

• IT IS SUITABLE FOR :
• Installation in tunnels dug using conventional methods (involving explosives),
providing it is placed in a consolidated and lined part of the tunnel;
• Installation on the back-up trucks of the tunnel boring machines(TBM),
providing it is placed in a consolidated and lined part of the tunnel.
• Installation in mines.
FOR A SAFE USAGE IT MUST BE INSTALLED:
• At a minimum distance of 500 meters from the drilling face
• At a minimum distance of 50 meters from deposits of combustible
materials.
• In consolidated and lined tunnel only.
• Where there is no risk of partial or total flooding.
• With a dedicated preferential electric power supply line.
• With telephone line connected to the site network.
• With a dedicated compressed air line.
In case of installation on the TBM the refuge has
to be placed in the safe place as defined by the
TBM manufacturer.
• IT MUST BE NOT INSTALLED IN THE FOLLOWING CASES:
1. IN STRETCHES OF TUNNEL THAT HAVE NOT BEEN CONSOLIDATED, WHERE THERE A RISK OF RUBBLE FALLING FROM THE
CEILING.
2.IN STRETCHES OF THE TUNNEL UNDER RISK PARTIAL OR TOTAL FLOODING.
3. IN ALL CASES REQUIRING A HIGHER SAFETY LEVEL THAN THE ONE PROVIDED BY THESE UNIT

• IT MUST NOT BE USED:

1. A ROOM FOR RECREATIONAL PURPOSES, AS A CANTEEN OR DORMITORY, CHANGING ROOMS, TOILETS, LIVING
ACCOMODATION, CLOAKROOM, OFFICE, INFIRMARY, STORES AND LABORATORY.
2. ANY USE OTHER THAN THE ONE FOR WHICH THE UNIT WAS INTENDED, OR NOT SPECIFICALLY MENTIONED IN THE
MANUAL.
2. INSTALLATION
2.1 POSITIONING
• PLACE THE REFUGE CHEMBER WITH THE ACCESS DOOR FACING TOWARDS THE TUNNEL ENTRANCE TO THE TUNNEL OR THE MAIN MINE ACCESS.
• PLACE THE REFUGE CHAMBER ON THE FLAT SO THAT DOOR OPENS EASILY.
• DO NOT INSTALL THE UNIT CLOSE TO FLAMMABLES STRUCTURES.
• DO NOT DEPOSIT ANY FLAMMABLE MATERIALS OR FLUIDS CLOSE TO THE REFUGE CHAMBER.
2.2 CONNECTING THE TUNNEL COMPRESSED AIR
• THE CONNECTION TO THE COMPRESSED AIR SUPPLY , PLACED ON THE BACK SIDE, IS MADE BY MEANS OF 1” GAS GALVANIZED STEEL PIPING.
CONTINUATION…
• USING FLEXIBLE CONDUIT IS NOT ALLOWED.
• THE MAX. ALLOWABLE PRESSURE AT THE COUPLING IS 7.5 BAR (108.778 PSI), THE MINIMUM ALLOWABLE PRESSURE IS 5 BAR (72.5189 PSI) AND THE MINIMUM
FLOW RATE TO GUARANTEE IS 200 Nm3 / h.
• The compressed air must be unpolluted and come from outside the tunnel. It is important for the air to be dried to avoid any condensation in the filters.
2.3 CONNECTING THE ELECTRIC POWER SUPPLY LINE
• Make connection to the dedicated power supply line through the dedicated entry placed on the front (check the power voltage allowed on the electric diagram
supplied)

Power supply
telephone
Continuation….
2.4 CONNECTING TO THE TELEPHONE LINE
• Connect the industrial telephone to the main telephone line in the tunnel. Follow the instruction given on the telephone operation manual which is provided
together with the refuge chamber manual.
2.5 PUT IN SERVICING AIR CONDITIONING

2.6 CONNECTING THE EARTHING AND EQUIPOTENTIAL LINE

 Continuation…
2.7 REFILLING THE OXYGEN CYLINDER
• Close all the valves Disconnect pip e from the cylinder

• Remove the cylinder

• When refilled, place cylinders in their own base and reconnect pipe
• Open valve and check if any loss is present
• Close all the valves
Cylinders pressure is 200 bars
Make the oxygen cylinders refilled by authorized refilling only.
3. ENABLE THE REFUGE CHAMBER FOR THE
EMERGENCY
3.1 UPS - (Uninterruptible Power Supply) A device that provides battery backup when the electrical power fails or drops to an unacceptable voltage level.
• Turn on the UPS following the procedure posted inside the chamber.
1. Close circuit breaker named “ battery breaker” behind the UPS.
2. Close circuit breaker named “input on-off “ behind the UPS.
3. Close battery switch mounted external the UPS.
4. Close the circuit breaker named” UPS Supply” mounted on low distribution board.
5. The UPS is now in by-pass mode.
6. Push the button “on-off” in front of the UPS. Select “on” and confirm with “enter”
7. Wait synchronization of the UPS.
• Turn on the battery load break switch placed above the UPS if present.
Continuation…
3.2 AIR CONDITIONER
• Turn on the air conditioner in cooling mode at a temperature of 30°C.
3.3 PROGRAMMABLE LOGIC CONTROLLER (PLC ) is an industrial computer control system that continuously monitors the state of input devices and makes decisions
based upon a custom program to control the state of output devices.
Open the PLC cabinet door, bottom side, and turn on the following switches.
• Main circuit breaker
• Air conditioner breaker
• Fan breaker
• Main lighting circuit breaker
• PLC Circuit breaker
Continuation…
3.4 PRESSURIZING THE UNIT
• Close completely the main entrance door
• Open the main air inlet valve (1) and set the minimum pressure through the manual regulator (2) at 0.25 bar (3) this value can be raised up to increase the airflow
rate if you wish to obtain an higher ventilation flow rate or a greater heat dissipation. Important: the first pressure gauge (3) INDICATES THE PRESSURE of incoming
air (from 6 to 7.5 bar) max. the second 0ne (4) shows regulated pressure.

3 1 2 4 5

• Overpressure inside the refuge should be kept from 200 to 250 Pascal. Check the overpressure through the differential pressure gauge (5).
• In case the noise generates discomfort, use earplugs.
The airflow that let the over pressure inside the unit let also to clean the air by the elimination of the
CO2. has to be always enough to clean the air. Air quality is monitored by the PLC.
THE REFUGE CHAMBER HAS TO BE ALWAYS PRESSURIZED.
4. USE EXTERNALLY SUPPORTED MODE
ALL SYSTEM ARE ENABLED AND SUPPLIED BY EXTERNAL SOURCE:POWER SUPPLY, COMPRESSED AIR, PLC

4.1 DOOR – CLOSE THE DOOR PROPERLY

4.2 LIGHTS – TURN ON INTERNAL LIGHTS THROUGH THE SWITCH PLACED ON THE LOW VOLTAGE SWITHCBOARD. TURN ON EXTERNAL LIGHTS THROUGH THE SWITCH
PLACE ON THE PLC.
4.3 SIREN – SIREN IS AUTOMATICALLY ACTIVATED AT THE START OF AN EMERGENCY BREATHING SYSTEM. SIREN CAN BE MANUALLY TURN OFF THROUGH THE SWITHC
PLACED ON THE PLC.
4.4 AIR CONDITIONER – TURN ON THE AIR CONDITIONER IN COOLING MODE AT A TEMPERATURE OF 30° C.
4.5 PRESSURIZATION – PRESSURIZED THE UNIT IF NOT DONE BEFORE. GO TO POINT 3.4
4.6 RESCUE – TAKE YOUR SIT, FOLLOW THE PLC INSTRUCTION AND WAIT FOR RESCUE.
5. USE IN STAND ALONE MODE
POWER SUPPLY AND COMPRESSED AIR FROM EXTERNAL SOURCE ARE NO MORE AVAILABLE. THE UPS IS THE AUTOMATICALLY ACTIVATED. THE EMERGENCY BREATHING SYSTEM
HAS TO BE MANUALLY ACTIVATED.
5.1 DOOR – CLOSE THE DOOR PROPERLY
5.2 LIGHTS – TURN ON INTERNAL LIGHTS THROUGH THE SWITCH PLACED ON THE LOW VOLTAGE SWITHCBOARD. TURN ON EXTERNAL LIGHTS THROUGH THE SWITCH PLACE ON
THE LOW VOLTAGE SWITCHBOARD.
5.3 SIREN – SIREN IS AUTOMATICALLY ACTIVATED AT THE START OF AN EMERGENCY BREATHING SYSTEM. SIREN CAN BE MANUALLY TURN OFF THROUGH THE SWITHC PLACED ON
THE LOW VOLTAGE SWITCHBOARD.
5.4 AIR CONDITIONER – TURN ON THE AIR CONDITIONER IN COOLING MODE AT A TEMPERATURE OF 30° C. THIS CONDITION IS MANDATORY FOR THE CORECT FUNCTION OF THE
CO2 ABSORBERS.
5.5 EMERGENCY BREATHING SYSTEM - OPEN COMPLETELY THE VALVES OF OXYGEN CYLINDER(6A).OPEN COMPLETELY PRESSURE REDUCER TAP 1.5 BAR (6B). IN CASE OF FAILURE
OF THE AUTOMATIC VALVE, OPEN AND CLOSE THE MANUAL TAP (6G) WHEN NEEDE TO JOIN THE VALUE OF 21.5 % READ THIS VALUE ON THE PLC DISPLAY.
5.6 CHEMICAL ABSORBERS
OPEN NO. 1 CO2 ABSORBER REMOVING ALL PACKAGE. ABSORBERS HAVE TO BE OPENED ONLY PRIOR TO USE. OPEN CO2 CARTRIDGE ONE BY ONE, WHEN REPLACEMENT
REQUIRED, CHECK THE GASKET ON THE BOX BOTTOM IS WELL PLACED. PLACE THE CO2 CHEMICAL ABSORBERS ON THE SCRUBBING UNIT WHERE PROPERLY INDICATED (6C) TURN
ON CO2 FAN THROUGH THE SWITCH PLACE ON PLC CABINET (6D). CO2 CARTRIDGE HAS TO BE REPLACED EVERY 3 TO 6 HOURS. FOLLOW PLC INSTRUCTION

IN CASE THE ALARM OF CO INSIDE THE REFUGE HAS GIVEN ALARM( ALARM IS GIVEN WHEN CO IS OVER THAN 60 PPM) OPEN THE CO CARTRIDGE . SHAKE THE CARTRIDGE AND
CHECK THE GASKET ON THE BOX BOTTOM IS WELL PLACED . PLACE THE CARTRIDGE ON THE SCRUBBER WHERE PROPERLY INDICATED (6E). TURN ON THE CO FAN THROUGH THE
SWITH PLACED ON PLC CABINET IN CASE CO ABSORBER HAS BEEN PLACED (6F).
DO NOT TURN OFF CO2 AND CO FAN FOR ALL THE TIME OF PERMANENCE INSIDE THE REFUGE CHAMBER

WHEN THE SCRUBBING SYSTEM STARTS UP, THE EXTERNAL SIREN HAS
AUTOMATICALLY ACTIVATED BY THE PLC.
5.7 RESCUE - TAKE YOUR SIT, FOLLOW THE PLC INSTRUCTION AND WAIT FOR RESCUE.
6. PLC FUNCTION
TURN OFF ACOUSTIC ALARM

TURN ON/OFF EXTERNAL SIREN

TURN ON/OFF CO FAN

TURN ON/OFF CO2 FAN

• 6.1 START UP – when turn on, the plc gives general alarm. Acoustic one can be stopped by pushing acknowledge button, while the visual
one is automatically stopped by the PLC itself further to data acquisition. This procedure takes 60 seconds, further to that the PLC is
operative.
• 6.2 CO2 – CO - O2 monitoring system - when enabled the plc takes under control the CO2, CO and O2 values, giving proper alarms when
limits are over/lower.
• 6.2.1 CO2 alarm – concentration is at 2.5 % even if CO2 scrubbing system is running. Acoustic and visual alarm are given simultaneously.
Acoustic can be manually stopped by pushing the button acknowledge placed on the plc door cabinet, while the visual one only when the
level has gone to the acceptable value. PLC give the instruction to evacuate the refuge.
• 6.2.2 CO alarm – concertation over 60 ppm. PLC advise to place the CO absorber on the scrubbing unit. Concentration is up to 200 ppm
even the CO scrubbing unit is running. Acoustic and visual alarms are given simultaneously. Acoustic one can be manually stopped by
pushing the button acknowledge placed on the PLC door cabinet, while the visual one only when the level has gone to the acceptable value.
PLC gives the instruction to evacuate the refuge chamber.
• 6.3 Oxygen Addition – oxygen addition is activated when the O2 concentration is at 20 %. The system automatically sprays oxygen through
the opening of the solenoid valve the right concentration has been restored.
• 6.4 Some Alarms
• 6.4.1 O2 closed or empty
This signal means that:
• At the start of the emergency breathing system, valves on cylinders and pressure reducer have not been opened. Open valves and pressure
reducer. Further to the use cylinders are empty. When oxygen level is going down 19 % evacuate the refuge.
• 6.4.2 Check CO2/CO cartridge position
• The signal displayed when the differential pressure gauge device control does not notice any pressure in the plant. It means that,
• The cartridge has not been well positioned: remove and position it again in the right position. Fan breakdown: place the CO2 cartridge in
the plant with the fan which is still working.
• 6.4.3 CO2 low pressure – CO low pressure
• This signal is displayed when the differential pressure gauge device control does not notice any pressure in the plant . It means that:
• The cartridge has not been well positioned: remove and position it again in the right position. Fan breakdown: place the CO2 cartridge in
the plant with the fan which is still working.
• 6.4.4 Sensor faulty
• The signal that arrives from sensors (CO-CO2-O2) is not valid (sensor damaged)
• The signal is not available (over the maximum level indicated)
7. MAINTENANCE
This activity has to be performed monthly.
7.1 DOORS
7.2 PRESSURIZATION
7.3 PLC  IN CASE ANY OF THIS CHECK WILL NOT BE SUCCESSFUL,
7.4 CHEMICAL ABSORBER AND NO SOLUTION CAN BE REACHED ON SITE, KEEP IN
7.5 CO – CO2 – O2 SENSORS CONTACT WITH WE WALTER SERVICING.
7.6 OXYGEN CLYNDERS  AN YEARLY INSPECTION BY WE WALTER SERVICING IS
RECOMMENDED.
7.7 SCRUBBING UNIT
7.8 UPS BATTERIES
7.8 AIR CONDITIONER
7.9 LIGHTS
Purpose of a refuge chamber
Protection from irrespirable atmospheres
Nature of the Hazard
Events that can give rise to an irrespirable atmosphere in an
underground tunnel include:
• fire
• explosion – blasting or sulphide dust
• inadequate or loss of ventilation
• flooding
• inrush of mud or tailings
• gas outbursts or intercepts
• extensive collapse of workings
• dust
• contaminated atmosphere (old workings).
Fire is the most common cause of incidents leading to the use of refuge chambers.
Potential sources of ignition in an underground tunnel include:
• heat energy (e.g. high temperature surfaces on engines, exhaust systems, pumps
and turbochargers, naked flames from welding equipment, cigarettes and matches)
• electrical energy (e.g. electrical discharge in motors, retarders and transformers,
short-circuit arcs, earthing faults, static electricity discharge), induction heating and
pyrolysis of tyres
• mechanical energy (e.g. cutting, friction, mechanical impacts, grinding)
• chemical reactions (e.g. self-heating, auto-ignition, exothermic reactions).

Inundation and inrush scenarios

Underground refuge chambers that are not designed to cope with the effects of
submersion may not function as intended when flooded or engulfed in liquefied
materials. It is therefore important that such chambers are located so they are not
affected by flooding or other inrush events
 Fire scenarios
The widespread use of diesel-powered and electrical equipment in underground tunnel means that the
provision of tunnel-wide compressed air reticulation systems has progressively diminished, and the inventory
of combustible materials has changed in both type and quantity. Most underground tunnel now have
significant stocks of diesel fuel, hydraulic oil, rubber (as tyres), polyvinyl chloride (as cable sheathing and
piping), and resin-based composite materials used for various machine enclosures.
The initial problem confronting an underground worker in the event of a fire is securing an immediate supply
of breathable air. This is normally addressed by supplying underground personnel with an oxygen-generating
self-contained self rescuer (SCSR). These devices allow a person to travel from an endangered position to a safe
haven, such as a refuge chamber, where one exists in reasonable proximity. This should be determined through
a risk assessment, taking into account the distance to the refuge chamber and the operating time of the self-
rescue unit.
Procedure in case of fire in the end of the
back up before the refuge chamber.
Refuge chamber

Fire build-up in this area

1. Warn people nearby to immediately evacuate the area. Set off the fire alarm or call shift boss. DO NOT
attempt to salvage equipment or objects – you are putting yourself at risk. DO NOT attempt to put out the
fire if the fire is huge.
2. Go directly to the assembly point/refuge chamber then make a call to tally control officer to report the
incident and to call for help.
3. Follow the instructions given over the tally control office/HSE/supervisor/fire fighting team leader.
4. Follow the procedure in operating the refuge chamber. Wait for the rescue.
Procedure in case of big fire in the front of
the back up after the refuge chamber.
Refuge chamber

Fire build-up in this area

1. Warn people nearby to immediately evacuate the area. Set off the fire alarm or call shift boss. DO NOT
attempt to put out the fire if the fire is huge. DO NOT attempt to salvage equipment or objects – you are
putting yourself at risk
2. Go directly to the exit point. Use the nearest exit, as long as it is free from smoke; otherwise, seek another
evacuation route.
3. If there is smoke, crawl out of the tunnel. (due to wind direction of the tunnel)
4. Call the tally control office/HSE/supervisor/fire fighting team leader when reaching the telephone along the