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Case Study on Gas Emission and induced Explosion during Tunnelling in

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Conference Paper · October 2014

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8th Asian Rock Mechanics Symposium ARMS8
14-16 October 2014, Sapporo, Japan

Case Study on Gas Emission and induced Explosion during Tunnelling in

Taiwan
C.H. Leea,b* and T.T. Wangb
a
United Geotech, Inc., Taiwan
b
National Taipei University of Technology, Taiwan
* ug513@mail.ugi.com.tw (corresponding author’s E-mail)

Abstract

This manuscript introduces a gas-induced accident in the west tunnel of Tsengwen Reservoir
Trans-basin Diversion project (TRTD). Tunnelling sections with problematic gas emission have been
investigated and paid attention during design stage, with gas detection instruments and associate
hazard mitigation measures prepared. However, excavation of tunnel run into gas outburst, with
methane concentration reaching 844,535 ppm revealed by Gas Chromatography-Flame Ionization
Detector (GC-FID), resulting in a severe explosion at the cost of 2 workmen. Due to two other
sections to be excavated have similar engineering geology conditions, the TRTD project was then
reviewed and associate with a strict and comprehensive gas-related hazard mitigations design
modification. Lessons learned from the gas emission and associate hazard are discussed and
commented.

Keywords: Tunnelling in Rock, Gas emission, Explosion, Geological Investigation

1. Introduction
Emission of hazardous gas during tunnelling can cause catastrophic hazard and have been
classified into one of unfavorable geological conditions for many tunnelling projects worldwide.
Various theoretical and empirical approaches, based on geological investigation results, have been
proposed for identifying or predicting the ground with potential hazardous gas problems before tunnel
construction. However, the increase of hazardous gas related accidents, especially wide-spreading
from coal mine to traffic or hydraulic tunnels, shows that the gas emission and related explosive
potentials should be paid more attention for tunnelling tasks.
Gas outbursts are mainly affected by the stress, gas, physical properties of the rock mass,
production process and so on (Beamish and Crosdale, 1998; Cao et al., 2001; Huang et al., 2010).
Kidybinski (1980) proposed the presence of three precursor zones in the coal seam ahead of the
roadway face: (1) broken zone, (2) high gas pressure/active zone and (3) abutment stress zone, and
concluded that gas outburst would occur when the three fundamental conditions meet with each other.
Williams and Weissmann (1995) describe the coal and gas outburst by emphasizing on the gas
pressure and stress gradients existing ahead of the excavated face.

2. Statistical analysis of cases

2.1 Characteristic of gas
Tunnels excavated into ground formations with hidden flammable or non-flammable gases may
cause hazards such as explosion, hypoxia, and poisoning. Flammable gases are primarily composed of
petroleum-based gases (mostly methane, with small amounts of ethane, propane, and butane),
coal-based gases (almost entirely methane), water-soluble natural gases (methane is water-soluble),
and biogas (mainly methane). In summary, methane (CH4) is the flammable gas mostly likely to be
encountered during tunnelling.
Methane is a colorless, odorless, and tasteless gas with a light density of 0.679 g/l, and has an
auto-ignition point of approximately 537°C, and product explosions at 5-15.4% concentration when
fire is present. The explosive power of methane is the strongest at 9% concentration. When methane
concentration is lower than 5% or higher than 15.4%, blue colored flame and black smoke will appear
around the ignition source, but will not extend to other areas or produce explosion. Methane
explosions absorb a large amount of oxygen and create low oxygen conditions inside the tunnel, and
8th Asian Rock Mechanics Symposium ARMS8
14-16 October 2014, Sapporo, Japan

even worse, create CO, which is harmful to humans. Methane explosions produce high temperatures
(approximately 2000°C), extremely powerful pressure (7 kg/cm2), and strong winds. The center of the
explosion is a vacuum, which causes a strong backflow of wind into the tunnel (CPAMI, 2000).

2.2 Statistical analysis

This study integrates 80 tunnelling cases collected by Kang (2009) and Ding (2010) as a database
for gas emission or explosion during tunnelling. Among which, 50 cases with gas measurement
records (Table 1) are selected for statistical analysis. Results of statistical analysis show that: (1) eight
cases of database did not pass through any coal layer, but still had gas overflow; (2) two of these
tunnels are not located in gas regions, but still had gas overflow and combustion phenomenon; (3) the
higher the gas pressure, the greater the quantity of gas, as shown in Fig. 1(a); and (4) the greater the
gas pressure, the higher the gas concentration, as shown in Fig. 1(b). Potential gas overflow is not
limited to tunnels that pass through a coal layer; tunnels that pass through fault fracture zones or
anticline sedimentary rock zones can also encounter potential gas overflow hazards.

Table 1 The cases of gas emission or explosion in tunnel.

Tunnel name Length Overburden Coal seam Gas region Gas content Gas emission Gas pressure Gas concentration Gas burning
No. (m) (m) thickness (m) (MPa) (%) / explosion
(m3/t) (m3/min)
1 Bailongshan 4845 600 0.8 High gas area 10.84 - 1.17 - -
2 Baishatuo No. 3 761 - - High gas area - - 0.37 4.85 -
3 Baishatuo No. 4 2118 300 - High gas area - - 0.78 10 -
4 Darroliangzi 4360 800 1.2 High gas area - - - 10 Gas escaping & burning
5 Faer 1241 100 2.13 High gas area 10.03 - - 11 -
6 Fenshui 4747 300 0.9 High gas area - 5 0.96 19 -
7 Fungshuepai 719 300 1.5 High gas area 4.14 - 0.87 - -
8 Hejiazhai 2335 280 2 High gas area 13.5 - 2.3 - -
9 Hongshiyan 7857 560 - Non gas area - - - 1.09 Gas burning
10 Hongfu 1527.5 - 0.15 High gas area 18.46 1.216 - - -
11 Huayingshan 4714 800 2.55 High gas area 9.16 - 1.87 - -
12 Hwangcho 7186 800 - Low gas area - - 0.258 0.3 -
13 Huanglianpo 5036 - 0.03 High gas area - 0.43 0.74 1 -
14 Huiyu 3455 - - High gas area - - - 0.3 -
15 Jiazhuqing 4990 500 4.38 High gas area 14.17 - 1.34 - -
16 Jiaoling 1655 250 - High gas area - 4.93 - - -
17 Jindong 9108 1000 1.05 Low gas area 8.741 0.498 2.192 - -
18 Liangfengya 4085 550 - High gas area - - - 0.7 Many times of gas burning
19 Longxi 3691 839 - High gas area - - - 5 -
20 Longyanjing 933.5 280 - High gas area - - - - Gas explosion
21 Mawangcao No.1 1266 550 0.72 Low gas area - - - 3 -
22 Meihuashan 3968 600 - High gas area - - 2 - -
High gas area One time of gas burning; two
23 Paotaishan 3078 400 - 3.03 - 0.2 -
times of gas explosion
24 Paozilin 6460 500 - High gas area - - - 0.7 -
25 Qiyueshan 10528 670 - Low gas area - - 0.14 1.2 -
26 Qingshan 4268 1000 - High gas area 9.35 - 2.24 - -
27 Shangqinghe 4238.29 300 - High gas area - 4 0.92 15 -
28 Sunjiazhai 533 90 5 High gas area - - - 1.5 -
29 Tianshengqiao 2450 - - High gas area 9.62 - 1.2 5.2 -
30 Tiefengshan 6030 630 - Low gas area 2.16 - 0.15 - -
31 Dingtonggou 2196 - - Non gas area - - - 1.3 Gas burning
32 Tongyu 4289 1000 2 Low gas area - 2.98 - - -
33 Wulong 9418 500 - High gas area - 0.8 - 60 Gas burning
34 Xishanping 1520 - - High gas area - - - 0.8 -
35 Xiaojiapo 2730 460 - Low gas area - 4.69 - 80 -
36 New Dabashan 10638 790 2 Low gas area - - - 0.5 -
37 New Shiyakou 1152 400 2 High gas area - - 1.4 - -
38 New Suzhai 698 200 0.8 High gas area - - - 0.64 -
39 New Yanjiaozhai 2641.5 - 7.1 High gas area 15.2 - 2.5 - -
40 New Zhai 4409 450 160 High gas area 15.779 - 1.82 - -
41 Yanjiaozhai 2714 - 8.92 High gas area - - 0.4 - Five times of gas explosion
42 Yesanguan 13791 1350 - High gas area - - 0.58 - -
43 Youyi 950 209 - High gas area - 0.857 - - Gas explosion
44 Yuanliangshan 11068 780 0.5 Low gas area - - 0.9 - -
45 Yuntaishan 8178 350 1.84 Low gas area - 4.03 0.18 - -
46 Zenjiaping 2477 500 - Low gas area 0.044 - - 8.2 Gas burning
47 Chuga 5194 370 2.1 High gas area - - 1.7 12.5 -
48 Zhongliangshan 3165 275 - High gas area 181.09 50 4 - -
49 Zipingpu 4090 550 0.3 High gas area - 3.19 0.67 - -
50 Zoumaling 2469 400 0.13 Low gas area - - 0.529 - -
8th Asian Rock Mechanics Symposium ARMS8
14-16 October 2014, Sapporo, Japan

18
16
14 y = 7.5954x0.6239

Gas content (m /t)
R2 = 0.7981
3
12
10
8
6
4
2
0
0 0.5 1 1.5 2 2.5 3
Gas pressure (MPa)

(a)

20
18
y = 7.4397x1.257
Gas concentration (%)

16
14 R2 = 0.4918
12
10
8
6
4
2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Gas pressure (MPa)

(b)
Fig. 1. Relationship between (a) gas content and gas pressure and (b) gas concentration and gas
pressure from the studied database with gas emission or explosion during tunnelling.

3. Case study in Taiwan

3.1 Project background
The Tsengwen Reservoir Trans-basin Diversion project (TRTD) near the Qishan river area has
many spots with natural gas emissions through veins, for example, the Shanminhuo in Minzu village.
The Chinese Petroleum Corporation (CPC) has performed a petroleum survey of the geological
structures near the study are for the potential gas reserves. The major gas-related geological structures
includes the Honghuazhi anticline and the Zhuqi structure, which are revealed by the Shanminhuo and
Jiasian number 1 well. Only the Zhuqi anticline had records of petroleum gas production prior to
1945; however, because production quantity drastically declined, it was abandoned in 1968.
Although the petroleum gas in this area does not reach economic exploitation magnitude, it can
still pose a threat during tunnel excavation. Furthermore, other geological drilling surveys have
detected harmful gases at the Laorenxi anticline, Pingxi fault, and the Biaohu fault (including CO and
CH4). Which indicates that tunnel construction may encounter problems caused by harmful gas
overflow.

3.2 Gas emission and the induced explosion

In response to gas overflow during tunnelling, which may impact the work environment and
worker safety, contractors conduct coring or non-coring survey in sections with high gas emission
potential. Furthermore, a fixed gas detector have be placed every 500 meters in the tunnel and 2
portable gas detectors have be carried during excavation to detect possible overflow of harmful gases
during construction. All workers for this tunnelling project have be educated with skills for safety
operations in potential gas emission environment.
8th Asian Rock Mechanics Symposium ARMS8
14-16 October 2014, Sapporo, Japan

Unfortunately, the west excavating face of the west diversion tunnel of TRTD project run into a
flammable methane gas explosion at the 13k+300 mark (between the second and third Pingxi fault
fracture zone, shown in Fig. 2) that caused the death of two engineering personnel and delayed the
construction in November 2007 (Xiao et al., 2009).

Fig. 2. The cross-section of gas explosion location in west diversion tunnel of TRTD project.

3.3 Investigation
Gas sampling and analysis was then conducted at Charshan and Shanminhuo in May 2007. Gas
Chromatography-Flame Ionization Detector (GC-FID) and Gas Chromatography-Thermal
Conductivity Detector (GC-TCD) analysis results showed that the gas collected at these two locations
contained mostly methane (84.6355 and 80.7038 % and 761996.00 and 715869.00 ppm, respectively).
Additionally, oil sampling and analysis was conducted at the TRTD project 13k+547 mark in August
2007. Gas Chromatography-Mass Spectrometry (GC-MS) instrument analysis showed that this oil
contained 23.0 vol % gasoline, 74.0 vol % kerosene and diesel, and 2.5 vol % reduced crude.
Sampling and analysis were conducted on oil and gas that seeped out at the TRTD project
13k+300-400 marks in January 2008. Table 2 shows the instrument analysis results of the sampled
gas. The gas contained 844,535 ppm of methane, which accounted for 94.8616% of the gas. This is
similar to the samples collected at the Charshan and Shanminhuo, which also contained mostly
methane. Oil samples from the 13k+300-400 mark were analyzed with GC-MS instrument. The total
ion chromatogram showed that the oil is composed of dark brown suspended emulsion and oil slick.
The oil components consist of light and medium oil. This conformed to the soil sample collected at
Charshan and Shanminhuo prior to the accident, which also consisted of light and medium oil (Weng
et al., 2009).

Table 2 The analysis result of GC-FID.

Site Methane Ethane Propane

(ppm) (ppm) (ppm)
TRTD 844535.00 31669.70 3544.18
Chashan 761996.00 53400.70 24620.20
Sanminhuo 715869.00 27842.30 10524.70
8th Asian Rock Mechanics Symposium ARMS8
14-16 October 2014, Sapporo, Japan

4. Design feedback and construction management

4.1 Design feedback
The accident during tunnel and associated supplementary investigations leads to a design feedback.
The level of gas explosion hazard during tunnel are proposed and estimated by five factors including
geological lithology (G), geological structure (S), coal seam thickness (T), overburden (O),
hydrogeological (H) (Ding，2010). Thickness of lining exceeding 30 cm is recommended for Level III
(potential danger) or IV (no danger) section. Blower type ventilation system is adopted for ventilation
during tunnelling and construction machines and equipment in tunnel section with gas explosion are
optionally changed to be non-explosion-proof types. Additionally, Thickness of lining exceeding 40
cm is recommended for Level I (extremely dangerous) or II (dangerous) section, and vertical and
incline shafts or pilot tunnel forced ventilation are suggested during tunnelling. The electrical
equipment and machines used in the tunnel are mandatory changed to explosion-proof types, and
fixed hazardous gas detectors must be set at fixed distances during construction period. After each
excavation cycle, portable gas detectors (which should be carried by all workers) are used to detect
concentrations of hazardous gases.
If overburden or topography limits the use of vertical shafts, inclined shafts, or pilot tunnels for
ventilation, the gas prevention grouting is suggested as an alternative for areas with high gas emission.
Typically, gas prevention grouting method with deep boreholes is used where holes are drilled in the
tunnel excavation surrounding area. Then grouting materials, can be cement, polyurethane resin, or
silicate resin, is then injected into the holes from top to bottom. Validation check of grouting effect is
carried out after the completion of grouting. If gas emission is still detected, then gas prevention
grouting on the excavating tunnel surface is launched.

4.2 Construction management

Considering with the gas-induced explosion during tunnelling needing the combination of three
conditions, i.e., flammable gas in explosive concentrations, adequate oxygen, and an ignition source,
the post-explosion improvement measures focusing on mitigation of such a combination are proposed
as follows (Xiao et al., 2009).
1. Supplementary geological investigations for the section subsequently tunnelling to have in
hands the distribution and quantity of hazardous gases, including tunnel horizontal coring or
non-coring exploratory drilling for the entire line to investigate concentrations of hazardous gases,
coordinate drill rod connections and test for gas (and keep records) every 3 meters. Exploratory work
should have at least 5 meters of parameter overlap.
2. Improving gas detection methodologies during tunnelling. The major part includes the
installation of a series of fixed gas detectors that can conduct automatic readings every 500 meters in
the tunnel. The detectors are moved to the top of the tunnel crown from their original height of 1.8 m.
Besides, portable gas detectors are setup every 100 to 150 m in the front of the tunnel excavation,
which can be adjusted based on the progress of the excavation. Additionally, the portable gas
detectors are raised to the crown of the tunnel with a telescopic rod and test for gas at every 250 m of
the tunnel to prevent measurement blind spots. Furthermore, ensure that tunnel drilling and blasting
operation includes a hazardous gas detection procedure.
3. If coagulated oil emits into the tunnel, clean up immediately or seal it off to prevent
accumulation of flammable gases.
4. Improvement of tunnel ventilation through increasing blower ventilation from 1500 m3/min to
1800 m3/min, increasing ventilation pipe from 120 cm ø to 140 cm ø, and increasing the air speed in
the tunnel from 0.2 m/sec to at least above 0.5 m/sec.
5. Ignition source control by adding flame arresters on construction machinery and vehicles, and
preventing lighters, cigarettes, and other ignition source from workers of the tunnel.
6. Implementation of flammable gas management standards (Table 3).
7. Strengthening the supervisor system, including establishing a supervisor’s checking procedure
for gas emission detection and explosion mitigation operation for various working faces, and the
mandatorily full participation of supervisor during tunnelling. Supervisors are responsible for various
command and control operations, including the implementation of flammable gas safety management
standards and tunnelling work suspending and evacuating personnel when blowers stop or ventilation
is inadequate.
8th Asian Rock Mechanics Symposium ARMS8
14-16 October 2014, Sapporo, Japan

Table 3 The construction management measures of hazardous gases inside tunnel.

Items Countermeasures
1. The fixed hazardous gas detectors are set at each 500 m and in front of the
Hazardous gas excavation face in addition.
detection 2. The fixed hazardous gas detectors are changed to automatically logger
equipment type.
3. The portable gas detectors are increased to 5 units per excavation face.
1. Gas detection position is increased to 4 points per excavation face.
Gas detection
2. Gas detection position is also located at each advancing exploration
position
borehole.
1. After each work shift.
2. Before each drilling and blasting.
Gas detection
3. After each drilling and blasting.
frequency
4. During each rockbolt drilling.
5. During each advancing exploration borehole.
1. The ventilation volume is increased to 1800 m3/min.
Ventilation
2. The diameter of ventilation tube is increased to 140 cm ø.
equipment
3. The wind speed in the tunnel is increased to 0.5 m/sec.
Lighting facilities The lighting facilities are changed to explosion-proof type.
Construction Jumbos, excavators, trucks, spraying machines and other devices are installed
equipment Flame bane.

5. Conclusions
The TRTD project run into the accident of gas-induced explosion during tunnelling in Taiwan.
Although the cause is different from every case, occurrence of such an explosion generally need a
combination of three conditions, a flammable gas in explosive concentrations, adequate oxygen, and
an ignition source. Rescue and post-processing after a tunnel gas explosion is extremely difficult. If
tunnels cannot avoid areas with potential gas deposits, gas survey, gas concentration monitoring
system, safety management measures, increase ventilation to reduce concentration, and ignition
control measures are the foremost principles in handling gas overflow.
Statistical analysis results from gas-induced tunnelling problem in this study showed that potential
gas emission may occur in areas outside of coal layers. Tunnels that pass through faults or anticline
sedimentary rock regions may also encounter gas overflow hazards. Thus, the survey and design stage
should conduct gas explosion hazard level evaluations to assess ventilation method during tunnel
excavation. When necessary, gas prevention grouting must be prepared in coordination with specific
hazardous gas detection, construction management, emergency response measures to reduce potential
gas explosion risk to a minimum, thereby ensuring worker safety.

Acknowledgements
Authors would like to thank the Ta-Chen and Nishimatsu joint venture group for offering the data
and agreement for publishing this article.

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14-16 October 2014, Sapporo, Japan

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