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Trade & Investment – Mine Safety Issued Industry DRAFT November 2011

GUIDELINES

MINE WINDERS

PART 1: GENERAL REQUIREMENTS

MDG 33.1

This version has been submitted to the Coal Safety Advisory Committee (CSAC) and is issued for industry comment. Any comments should be forwarded by 30 November 2011 to Lyndon Hughes at: [email protected]

This guideline is expected to be published in December 2011.

MDG 33 Part 1_General_ Industry DRAFT 111028.doc

MDG 33.1 Page i

mailto:[email protected]

PUBLICATION HISTORY – First published October 1998 as MDG 33, for drum winders

– This Industry DRAFT, November 2011 now incorporates all winders.

DISCLAIMER

The compilation of information contained in this document relies upon material and data derived from a number of third party sources and is intended as a guide only in devising risk and safety management systems for the working of mines and is not designed to replace or be used instead of an appropriately designed safety management plan for each individual mine. Users should rely on their own advice, skills and experience in applying risk and safety management systems in individual workplaces.

Use of this document does not relieve the user (or a person on whose behalf it is used) of any obligation or duty that might arise under any legislation (including the Occupational Health and Safety Act 2000, any other act containing requirements relating to mine safety and any regulations and rules under those acts) covering the activities to which this document has been or is to be applied.

The information in this document is provided voluntarily and for information purposes only. The New South Wales Government does not guarantee that the information is complete, current or correct and accepts no responsibility for unsuitable or inaccurate material that may be encountered.

Unless otherwise stated, the authorised version of all reports, guides, data and other information should be sourced from official printed versions of the agency directly. Neither Trade & Investment, the New South Wales Government, nor any employee or agent of the Department, nor any author of or contributor to this document produced by the Department, shall be responsible or liable for any loss, damage, personal injury or death howsoever caused. A reference in this document to "the Department" or "Trade and Investment" is taken to be a reference to the NSW Department of Trade and Investment, Regional Infrastructure and Services.

Users should always verify historical material by making and relying upon their own separate enquiries prior to making any important decisions or taking any action on the basis of this information.

This publication contains information regarding occupational health, safety, injury management or workers compensation. It includes some obligations under the various workers compensation and occupational health and safety legislation that Trade & Investment administers. To ensure compliance with legal obligations, refer to the appropriate legislation.

In the event of inconsistency with a provision of any relevant Act or Regulation the provision prevails over the guideline.

This publication may refer to NSW legislation that has been amended or repealed. When reading this publication, refer to the latest laws. Information on the latest laws can be checked at:

www.legislation.nsw.gov.au

Alternatively, phone (02) 4931 6666.

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.1 Page ii

http://www.legislation.nsw.gov.au/

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.1 Page iii

FOREWORD Mine winders are important items of infrastructure in the underground mining industry and there are many installations operating in the NSW mining industry. These installations comprise many variations of design ranging from single rope drum vertical shaft and drift slope haulage systems and vertical shaft friction winder systems.

Mine winders are considered as high risk plant, the failure of which has potential for multiple fatalities. Some mine winders have potential to carry in excess of 150 people in a single lift. The MDG 33 guideline provides guidance in managing the risks associated with the design, commissioning and use of mine winders.

The application of mine winders range from those designed for personnel transport only to those designed for both personnel and materials transport duty and to those designed solely for the purpose of materials haulage. These winders are permanent items of the operational mine’s infrastructure. In addition there are shaft sinking winders required for relatively short term projects associated with the development of new or extension of existing underground mines.

This revision of MDG 33 is not limited to drum winders; it collates all winder types and includes information previously provided in MDG 12 ‘Guideline for the construction of friction winder’, MDG 2005 ‘Electrical technical reference for the approval of power winding systems’ and MDG 26 ‘Guideline for the examination, testing and discard of mine winder ropes’.

The guideline is provided in seven parts. This is part 1.

Part 1: General requirements

Part 2: Drift winders

Part 3: Vertical shaft winders

Part 4: Shaft sinking winders

Part 5: Friction winders

Part 6: Winder control systems

Part 7: Examination, testing & retirement of mine winder ropes

This is a “Published Guideline”. It provides an industry benchmark for engineering standards and fit-for-purpose equipment. It represents acceptable industry practice for reducing lifecycle risks associated with mine winders.

The guideline makes reference to the suite of Australian Standards that have been developed over the past years for mine winders. Adoption of this technical information and the appropriate use of risk assessment techniques should foster “Safe Winding Practices”.

The foundation work by the late Les Melane is gratefully acknowledged in the original publication of this guideline

A feedback sheet is provided in the Appendices. Constructive comment is essential to help the Department improve this Guideline.

CONTENTS

FOREWORD............................................................................................................................ iii

1 PURPOSE and SCOPE......................................................................................................... 1

1.1 Purpose................................................................................................................................................ 1

1.2 Scope ................................................................................................................................................... 1

1.3 Application............................................................................................................................................ 1

1.4 References........................................................................................................................................... 2

1.5 Abbreviations ....................................................................................................................................... 2

1.6 Definitions ............................................................................................................................................ 2

2 MANAGEMENT OF WINDERS............................................................................................. 5

2.1 Occupational Health and Safety .......................................................................................................... 5

2.2 Hazard Identification ............................................................................................................................ 6

2.3 Instruction, Training and Competencies .............................................................................................. 6

2.4 Supervision .......................................................................................................................................... 7

2.5 Audit, Monitor and Review ................................................................................................................... 7

2.6 Plant Safety File ................................................................................................................................... 7

2.7 Emergency Preparedness ................................................................................................................... 7

2.8 Accident Review................................................................................................................................... 8

2.9 Isolation and Energy Dissipation.......................................................................................................... 8

2.10 Safety Audits ...................................................................................................................................... 8

2.11 Operation of Winding Systems ........................................................................................................ 10

2.12 Winder Inspection, Maintenance and Repair................................................................................... 11

3 WINDER DESIGN and CONSTRUCTION .......................................................................... 12

3.1 Hazard Identification, Risk Assessment and Control......................................................................... 12

3.2 General .............................................................................................................................................. 13

3.3 Design registration Requirements...................................................................................................... 19

3.4 Loads ................................................................................................................................................. 19

3.5 Winding Speeds and Accelerations ................................................................................................... 19

3.6 Rope Selection................................................................................................................................... 20

3.7 Torque................................................................................................................................................ 23

3.8 Inertia ................................................................................................................................................. 23

3.9 Accelerating and Decelerating Torque .............................................................................................. 25

3.10 Winder Drum Design........................................................................................................................ 28

3.11 Shaft Design..................................................................................................................................... 35

3.12 Gears, Gearboxes and Couplings.................................................................................................... 37

3.13 Clutches ........................................................................................................................................... 41

3.14 Brake Calipers and Brake Supports ................................................................................................ 42

3.15 Handrails, Guards, Ladders and Stairways ..................................................................................... 43

3.16 Foundations ..................................................................................................................................... 44

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.1 Page iv

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.1 Page v

3.17 Headsheaves ................................................................................................................................... 47

3.18 Manufacture and Installation............................................................................................................ 51

3.19 Commissioning................................................................................................................................. 52

4 Operation ............................................................................................................................ 55

4.1 General .............................................................................................................................................. 55

5 Maintenance ....................................................................................................................... 57

5.1 General .............................................................................................................................................. 57

5.2 Maintenance....................................................................................................................................... 57

APPENDIX A references....................................................................................................... 58

APPENDIX B Mining Legislative Framework in NSW........................................................ 61

APPENDIX C - Design Registration Mine winders............................................................. 62

APPENDIX D Feedback Sheet.............................................................................................. 63

MDG 33.1 Guideline for Winding Systems at Mines

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.1 Page 1

1 PURPOSE AND SCOPE

1.1 PURPOSE

The purpose of the guideline is to protect persons against harm to their health, safety and welfare through the elimination or minimisation of lifecycle risks associated with mine winders

1.2 SCOPE

This guideline sets out recommended minimum lifecycle safety requirements for mine powered winding systems.

This guideline consists of seven parts. For the full range of recommendations for a mine winder, each relevant part needs to be considered.

NOTES:

1) For guidance on drift winders, see MDG 33.2.

2) For guidance on vertical shaft winders, see MDG 33.3.

3) For guidance on shaft sinking winders, see MDG 33.4.

4) For guidance on friction winders, see MDG 33.5.

5) For guidance on control of winders, see MDG 33.6.

6) For guidance on winder ropes, see MDG 33.7

This guideline is also intended to assist designers, manufacturers, design verifiers and owners of mine winders by indicating parameters that should considered in –

– the initial design and performance assessment of mine winders

– the independent design verification of mine winder

– five years periodic audits of mine winders

This guideline does not cover mining hoists used in gem fields, see MDG 42.

1.3 APPLICATION

This Guideline applies to the design, use and maintenance of all friction and drum mine winders.

This guideline should be used by designers, manufacturers, owners and users when –

(a) Designing new mine winders

(b) Independently verifying mine winders

(c) Applying for design registration of mine powered winding systems

(d) Altering existing mine winders

(e) Carrying out five yearly audits on mine winders

(f) Reviewing winder designs following an incident

(g) Operating mine winders

(h) Altering, maintaining, repairing or mine winders

1.4 REFERENCES

A list of reference documents is provided in APPENDIX A .

1.5 ABBREVIATIONS

For the purpose of MDG 33 Parts 1 to 7, the abbreviations below apply.

AS Australian Standards

AS/NZS Australian / New Zealand Standard

DIN German Standard

MRD Mineral Resources Division

MSOB Mine Safety Operations Branch

ISO International Organisation for Standardisation

JSA Job Safety Analysis

MDG Mechanical Design Guideline

MSDS Material Safety Data Sheet

PPE Personnel Protection Equipment

SAE Society of Automotive Engineers

SWP Standard Work Procedure

1.6 DEFINITIONS

For the purpose of MDG 33 Parts 1 to 7, the definitions below apply.

1.6.1 Competent Person / Competencies

Is a person who has, through a combination of training, education and experience, acquired knowledge and skills enabling that person to perform correctly a specified task.

1.6.2 Defect Management System

Is a system that outlines the actions to be taken when a defect is identified.

A defect management system documents instructions to be taken when a defect is identified and how the details of the defect and actions taken are recorded.

1.6.3 Must

Indicates that legal requirements exist, which must be complied with.

1.6.4 Shall

Indicates a strongly recommended course of action.

If compliance with this guideline is sought, then all shall statements ought to be complied with.

1.6.5 Should

Indicates a recommended course of action.

1.6.6 Engineering Standards

A set of engineering standards that is applied to the mine to ensure equipment is safe to use.



This includes competency of persons, design, installation, commissioning, operation, maintenance and decommissioning.

1.6.7 Powered Winding Systems

Means any lifting plant used to carry people for the purposes of allowing access to the underground workings of a mining workplace or a coal workplace or for the purposes of inspecting and maintaining the system or the mine shaft, but does not include manually operated plant or light portable winches

1.6.8 Drum winder

A shaft or drift winding system in which conveyances, skips, kibbles, or stages are raised and lowered by means of a single rope attached directly and winding onto a cylindrical drum, or drums in the case of double drum winding.

1.6.9 Friction winder

A shaft winding system in which conveyances and skips are raised and lowered by means of multiple ropes passing over a driving sheave such that the driving force is transmitted from the sheave to the ropes by friction.

1.6.10 Conveyance

Refers to any car, carriage, cage, skip, kibble, counterweight, or stage in which persons, minerals or materials are wound through a shaft.

1.6.11 Attachments

Components used to connect the conveyance to the end of rope. The components may include rope sockets, capels, pins, couplers, chains bars, detaching hook, rope swivels and swivel hooks and similar. (Refer AS 3637:1-6 and AS 3751:2005)

1.6.12 Mechanical Brakes

Includes all brakes other than the electrical braking by the motor control used to decelerate stop and hold a drum winder. (The brakes may be hydraulic, pneumatic or electrically operated)

1.6.13 Arrester System

An assembly, incorporating one or more arrestors, for decelerating and stopping the conveyance(s) within a winding system.

1.6.14 Overwind

Unintentional travel of an ascending conveyance beyond its normal operating limits.

1.6.15 Overwind Safety Catch System

A system of devices mounted in the headframe and on the conveyance to prevent the conveyance from falling an excessive distance after the conveyance has been brought to rest.

1.6.16 Headframe

The structure, including its footings, that supports the rope loads in a winding installation.

1.6.17 Dead load

The load due to the mass of the permanent components of a conveyance.

1.6.18 Live load

The load resulting from the operation of a conveyance.


1.6.19 Rated load

The maximum load a conveyance is designed to carry during normal use.

1.6.20 Chairing

Supporting of a conveyance at some point in its normal vertical path, by means other than the winding ropes or gripper system.

1.6.21 Guides

Stiff structural members or suspended steel wire ropes located in a mine shaft or sky shaft or both, to limit lateral movement of a conveyance.

1.6.22 Main load bearing Members

A component that lies in the load transfer path to attachments.

1.6.23 Sky shaft

A structure including, including its footings, that is primarily designed to support conveyance guides above a shaft collar and to with stand impact loads resulting from an overwind.

1.6.24 Fleet angle

The angle formed between the line of the rope and the normal line at its point of incidence on the drum or sheave, measured in the plane of the rope.



2 MANAGEMENT OF WINDERS

2.1 OCCUPATIONAL HEALTH AND SAFETY

2.1.1 Legislative framework

The OHS Act imposes a general obligation to ensure the health, safety and welfare of people at work through a process of identifying hazards, assessing risks and eliminating or control risks. In addition to the general duty of care, the OHS Regulation requires mine powered winding systems to be design and item registered.

The Occupational Health and Safety legislative framework for engineering safety on mine sites is represented by the diagram in Appendix B.

This diagram highlights the hierarchy of legislation and the legislative considerations when managing engineering safety on a mine.

2.1.2 OHS Act 2000 and OHS Regulation 2001

The OHS Act 2000 and the OHS Regulation 2001 requires:

Designers, manufacturers and suppliers of plant must:

ensure plant is safe and without risk to health or safety when properly used;

provide adequate information about the plant to persons to which the plant was supplied to ensure its safe use; and

identify any foreseeable hazards that have potential to harm health or safety, assess the risks and take action to eliminate or control the risks.

Employers must ensure the health, safety and welfare of its employees and others at the employer’s place of work through a process of risk management and consultation. That duty extends to:

ensuring that plant provided for use is safe and without risk to health when properly used,

ensuring that systems of work and the working environment are safe and without risk to health; and

providing information, instruction, training and supervision as necessary to ensure health and safety is provided,

NOTE:

1. This guideline provides guidance towards meeting these requirements.

2. Designers, manufacturers and suppliers of plant and employers are advised to consult the OHS Act 2000 and the OHS Regulation 2001, particularly Chapter 5 Plant, for details of these requirements.

3. To effectively consider this guideline, designers, manufacturers, suppliers of plant and employers need to be aware of these requirements and have systems and procedures in place to apply them.

2.1.3 Control of Risk

The OHS regulation requires risks that cannot be reasonably eliminated must be controlled in the following order: (a) Substitute the hazard for a hazard giving rise to a lesser risk.

(b) Isolate the hazard from people at risk.


(c) Minimise the risk by the use of engineering means.

(d) Minimise the risk by administrative means, (e.g. safe work procedures, training, instruction, information)

(e) Use of personal protective equipment (PPE)

NOTE: A combination of methods may be required to minimise the risk to the lowest level reasonably practicable.

2.2 HAZARD IDENTIFICATION

Identify the risk to health and safety of people associated with the powered winding system.

Identify the risk to equipment associated with the powered winding system.

All foreseeable hazards must be identified at the design and manufacturing stage and either eliminated, or controls established to minimise the risk.

2.2.1 Risk Assessment

The designer and manufacturers and suppliers must carry out a risk assessment to evaluate all risks to the safety of people from the use of the mine winding system. The designer and manufacturer must identify the design requirements and any other actions as required to control the risk in accordance with the hierarchy of risk controls.

This risk assessment shall be reviewed and an operational risk assessment carried out whenever alterations are carried out to the winding system or whenever a significant incident occurs

2.2.2 Risk Management Procedures

Jobs Safety Analysis (JSA), Safe Work Procedures (SWP) and similar, should be prepared for all activities relating to mine winding systems, where there is a risk to the safety to people.

They should be supplied by the Designer/ Manufacturer and maintained and developed by the Owner of the winding system.

2.3 INSTRUCTION, TRAINING AND COMPETENCIES

All persons involved with mine winding systems including designers, supervisors, operators and maintenance personnel should be trained and assessed for their competencies. Their training may vary depending on the hazard levels associated with the task being undertaken.

The minimum acceptable competencies for particular types of work should be nominated.

Records of training and assessments should be maintained and available for audit.

Persons with appropriate knowledge, skills and experience should carry out training.

2.3.1 Training

Training and assessment of competencies may include, but be not limited to the following:

(a) Knowledge and understanding of hazards and the required controls.

(b) Safety procedures, including emergency procedures.

(c) Operating, maintaining and repairing of the mine winding system.

(d) Energy isolation and depressurisation.

(e) Inspection and testing of the mine winding system



(f) Understanding the purpose and function of safeguards that protect personnel.

(g) Reporting of faults and defects.

(h) Use of protective equipment.

2.4 SUPERVISION

All employees who work on mine winding systems should be adequately supervised according to their competencies and the task at hand.

2.5 AUDIT, MONITOR AND REVIEW

Mine winding systems should be audited, monitored and reviewed at appropriate periodic intervals and when incidents occur for compliance to the design standards and this document.

2.6 PLANT SAFETY FILE

Safety related aspects of mine winders shall be fully documented. These records shall be maintained in a plant safety file which covers the lifecycle of the winding system.

The following records shall be maintained:

(a) design specifications, functions and other documents

(b) designs documentation for certification, registration, see clause xx

(c) hazard identification and risk assessment documents

(d) risk control methods

(e) consultation records

(f) component certifications and test certificates

(g) commissioning and test results

(h) Identification of all safety critical systems and their safety category or integrity level.

(i) maintenance records, safety inspections and test reports

(j) defects management system

(k) Change of procedures, monitoring, audit and review reports

(l) reports of accidents, incidents and safety statistics

(m) training and competency records

(n) winder modifications or alterations

The records shall be stored and maintained in such a way that they are readily retrievable and protected against damage, deterioration or loss.

A plant safety file may not necessarily be one complete document, and may refer to where the information can be obtained

2.7 EMERGENCY PREPAREDNESS

Action plans and procedures in the event of a mine winding accident shall be prepared.

Actions plans and procedures in the event of people being trapped in the conveyance in the shaft shall be prepared.


2.8 ACCIDENT REVIEW

A co-operative approach between Manufacturers, Statutory Authorities and Mine Operators is required to eliminate mine winding incidents.

The owners and operators of mine winding systems should provide to the equipment manufacturer, details of relevant incidents in relation to the equipment.

The Manufacturer should notify all owners and operators of any safety related incidents that they become aware of from time to time and their recommendation to rectify such defect. (E.g. Safety Alerts, Technical Bulletins, and similar.)

2.9 ISOLATION AND ENERGY DISSIPATION

Procedures should be supplied by the Manufacturer and maintained and developed by the Owner for the safe isolation and / or energy dissipation within the system. They should be available for all activities associated with the installation, commissioning, operation and maintenance of the mine winding system.

A person shall not carry out repairs to mine winding systems unless the energy source is isolated and cannot be reconnected accidentally before it is safe to do so.

The system of isolation adopted should incorporate a tagging system, a locking system or permit system and in any case should also include a method for ensuring that isolation and / or energy dissipation is effectively established.

Isolation and energy dissipation should be carried out in accordance with MDG 40 and AS 4024.1.

2.10 SAFETY AUDITS

2.10.1 Purpose

Every winder which has been in service for five years, or has been engaged in winding duties for a period not exceeding five years since its last audit, shall be audited.

NOTE: 5 yearly safety audits are a condition of design registration on powered winding systems.

The purpose of the audit, to be known as “the safety audit” is to have all safety requirements of the winder, and associated equipment and documentation being used with the winding activities, verified as acceptable, by an external and independent auditor.

Competent mechanical and electrical persons shall carry out the external audit.

2.10.2 Audit Procedures

The safety audit shall assess the safety condition of the winder and address/review all safety aspects of design, operation, servicing, testing and maintenance of the winder. The safety audit shall also review the management system that governs the use of the winder. It shall include, but not be restricted to, the following:

(a) Review winder certification and registration documents.

(b) Review design calculations, drawings, and specifications.

NOTE: For ongoing audits these documents may require only sighting where a previous audit indicates that the documents have been examined and are acceptable.

(c) Review the winder management plan.

(d) Review the maintenance management plan.

(e) Review the structural integrity inspection reports, their frequency and check that all components of the system are covered.



(f) Verify that all safety devices are in place and functioning and that a testing programme of all these devices is in place and is carried out on a scheduled basis. Verify that the records of these tests are accessible for inspection. List each device on a sheet, test for performance, and enter test results on the sheet.

(g) Verify that a brake testing program is in place and is current. Verify that static and dynamic brake testing records are kept and accessible for inspection.

(h) Witness winder static and dynamic brake testing and check that the deceleration rates comply with the recommendations within this document. Ensure that persons authorised to conduct these tests are fully conversant with the purpose and method of safely carrying out this testing.

(i) Review brake maintenance servicing records. Check the application times of the service and emergency brakes and with disc caliper type brakes the individual caliper application times. Check that the application times are as recommended by the manufacturer.

(j) Inspect vertical shaft conveyances, attachments, arresting devices, safety catches and all other safety components, and verify the acceptability of all safety features. Verify that the attachment testing frequencies and certification conforms to the appropriate Australian Standard.

(k) Inspect drift conveyances, attachments, conveyance brakes, safety chains, and all other safety components, and verify the acceptability of all safety features. Verify that the attachment testing frequencies and certification conforms to the appropriate Australian Standard.

(l) Examine all current rope Destructive and Non Destructive Test reports for compliance to AS 4812:2003 and MDG 26. Calculate the factors of safety for the strength of the rope at new and at the present strength. Visually examine the rope for any defects or anomalies.

(m) Examine the winder apparatus and brakes Non Destructive Test reports and verify the condition of the components and that the frequencies are in line with the number of winds a year of the winder. (A wind is defined as a single journey in a shaft or drift. Light, medium or heavy).

(n) Review all competency related documentation, with respect to the winder system for:

(i) Winding Drivers;

(ii) Operators; and

(iii) Maintenance Personnel.

2.10.3 Audit Approval

Any safety issue found during the audit, and needing attention, should be resolved with the mine manager and his/her representatives, and/or the winder owner in the case of a shaft sinking contract.

Where a difference of opinion arises as to the requirement of a safety device or the consequence of a perceived hazard, that cannot be resolved, then the auditor shall seek the advice of the local Department Inspector who will adjudicate.

To complete the audit, the auditor shall conclude the report with attachments which clearly indicate the safety condition of the winder. The auditor shall provide at least two copies of the report to the mine manager


Where sufficient time is not available to complete the audit by the due date, the mine manager may apply to have the time extended for up to six months.

Failure by the mine manager or owner to have a safety audit on a winder under his/her control completed could render the winder registration invalid.

2.11 OPERATION OF WINDING SYSTEMS

2.11.1 General

The owner and operator of a Powered Winding System shall develop a Management Plan that defines the procedures and standards applicable to the operation of the mine winding systems.

The Management Plan’s main operating features shall include:

(a) Risk assessment of the System

(b) Procedure for the Operation of the System

(c) Response plans

(d) Competency training of personnel operating the System

(e) Control for the replacement or addition of equipment to the System

(f) Communication process

(g) Documentation control and recording process

(h) Auditing the Management Plan’s effectiveness and adequacy

2.11.2 Operational Procedures

There is a requirement to have written procedures in place to manage the operations involved in the transport of men and materials using powered winding systems. The mine shall develop ‘Rules for Transport’. These rules are written operating procedures to manage the tasks and associated risks that have been identified in the use of the powered winding system.

The areas covered by these procedures include:

(a) Appointment of Drivers

(b) Inspections of the System

(c) Carriage of Personnel

(d) Carriage of Materials

(e) Securing of Loads

(f) Haulage Capacity Limits

(g) Speed Restrictions for Loads

(h) Persons Working in the Drift

These Operational Procedures make reference to Job Instructions, Standard Operating Procedures and Recording Sheets that define the details relating to individual processes.

2.11.3 Job Instructions/Standard Operating Procedures

Where a detailed written instruction is required to manage the tasks and associated risks involved with performing a specific job, a written standard operating procedure (job instruction) shall be developed.



These procedures are job specific and provide a step-by-step instruction to enable a trained and competent person to perform a specified task.

Job instructions are subordinate to management plan procedures.

The attention to job detail is more specific and ordered.

2.12 WINDER INSPECTION, MAINTENANCE AND REPAIR

2.12.1 General

The owner and operator of a mine winder shall develop a Management Plan that defines the procedures and standards applicable to the maintenance of the mine winding systems.

The Management Plan’s main maintenance features shall include:

(a) Risk assessment of the System

(b) Procedure for the Maintenance of the System

(c) Response plans

(d) Competency training of personnel maintaining the System

(e) Control for the replacement or addition of equipment to the System

(f) Communication process

(g) Documentation control and recording process

(h) Auditing the Management Plan’s effectiveness and adequacy

2.12.2 Maintenance Procedures

The management of maintenance for all equipment comprising the powered winding system shall utilise scheduled documents generated to satisfy the requirements of the Management Plan.

The schedules may be identified as being either:

(a) Statutory Maintenance The Statutory Maintenance Schedules cover all the inspections, examinations and tests required under the Standards of Engineering Practice; or

(b) Routine Maintenance The Routine Maintenance Schedules cover all other maintenance tasks, which includes condition based monitoring and performance testing of the equipment.

The results of the scheduled tasks shall be recorded as history for the specific equipment.


3 WINDER DESIGN AND CONSTRUCTION

3.1 HAZARD IDENTIFICATION, RISK ASSESSMENT AND CONTROL

3.1.1 General

Designers of mine winders must carry out a risk assessment(s) to –

a) identify all foreseeable lifecycle hazards associated with mine winder

b) evaluate/assess all risks of harm to the safety of any person arising from the identified hazards; and

c) implement appropriate risk controls and design requirements to control the risk to a level as low as reasonably practicable.

In designing risk controls the designer must make sure that –

(i) safe access to the components of the bolting plant can be gained for the purpose of operation, maintenance, adjustment, repair and cleaning; and

(ii) the designer has given regards to ergonomic principles.

The designers risk assessment must cover the lifecycle risks and should be carried out in consultation with the end user. The design risk assessment should consider reasonably foreseeable misuse and should review previous accidents, incidents relating to similar plant, where practicable.

The designers risk assessments must be reviewed whenever –

there is evidence the original risk assessment is no longer valid; or

they are provided with information regarding a design fault that may affect health or safety.

NOTE: Note: refer OHS Regulation 2001 Chapter 5.

3.1.2 Information by designer/manufacturer

The designer/manufacturer must provide information on risk controls necessary for the safe use of the mine winder. This information must include the following, but not be limited to –

a) information on identifying hazards, assessing risks arising from the hazards and controlling risks from the use of the bolting plant;

b) the purpose of the mine winder;

c) testing or inspections requirements;

d) installation, commissioning, operation, maintenance, inspection, cleaning requirements;

e) systems of work for the safe use of the mine winder; and

f) competence of people undertaking inspections / tests

g) emergency procedures.

This information should be contained in the plant safety file and should be provided before supply of the fan ventilation plant.




3.1.3 Safety Critical Systems

All safety critical functions required for the safe use of the mine winder shall be identified and documented by the designer.

Through a risk assessment process the designer should determine the required minimum safety integrity level or the required minimum category level for each identified safety function and should design an appropriate safety critical system to control the risk.

The assessment and validation of safety critical systems should be in accordance with an appropriate recognised standard, such as – AS 4024:1501 and AS 4024:1502, or AS/IEC 62061, or AS/IEC 61508 or other similar standards.

The validation risk assessment should be in the form which systematically analyses the failure modes and integrity of each safety critical system.

NOTES:

1) A Failure Modes and Effects Analysis (FMEA), fault tree analysis, quantitative risk assessment, or similar analytical systematic method may be used.

2) Guidance can be found in AS 4024.1301 and AS 4024.1302 and the National Minerals Industry Safety and Health Risk Assessment Guideline.

3.2 GENERAL

Mine winding systems should be designed, manufactured, constructed and tested using good engineering principles and engineering standards to ensure that the system is fit for purpose for the required duty.

Unless otherwise specified the appropriate Australian Standards shall apply.

Where reference is made to a design standard, the current published version shall be used.

Materials used in mine winding systems should be appropriate for the intended application and the environment likely to be encountered in service.

The design of the system shall include ladders, stairs, platforms and walkways to provide safe and convenient access to all parts and devices of the winding system that require inspection, examination and testing, adjustment cleaning or service.

Hydraulic fluid systems should be designed, manufactured and installed in accordance with AS 2671.

Pneumatic fluid systems should be designed, manufactured and installed in accordance with AS 2788.

All machinery and systems should comply with the relevant parts of the AS 4024.1 series of standards.

Any fire suppression or protection equipment installed shall meet requirements of relevant Australian Standards and legislation.

3.2.1 Design Documentation

The design documentation for the mine winding system shall be in accordance with clause xxx

3.2.1.1 Mechanical documents for assessment

The following documents (or documents containing the following information) shall be provided with the design registration application for mechanical assessment:

a) A detailed description of the powered winding system including:

(i) Purpose and description of use.

(ii) Designed, winding loads and speeds for both men and materials.

(iii) A functional specification on the controls of the powered winding system including all designed control, their limits and set points.

(iv) Identification of each component which constitutes the powered winding system.

(v) Operational requirements

(vi) Any other information pertinent to the safe operation of the powered winding system.

b) Representational documents of the powered winding system including:

(i) General arrangement drawings

(ii) Winding plant and conveyance drawings

(iii) Drawings or identification of the cable (rope) and associated attachments

(iv) All hydraulic and pneumatic control system drawings.

(v) Any other drawings or documents as required to clearly identify the powered winding system

c) Appropriate documentation on the design of each safety critical component of the powered winding systems including, but not limited to: the winding plant; the cable (rope) and associated attachments; the winder control system(s); the conveyances, and the supporting structures.

The documentation must include design calculations, drawings and certification as described above.

d) A requirement by requirement assessment of the winding system against the relevant parts of MDG 33, by a qualified mechanical engineer.

e) A risk assessment to verify the integrity of the winding plant under all operational and maintenance conditions, including the failure of components. (FMEA on the control circuit and other critical component).

NOTE: This risk assessment shall be in a form which systematically analyses the failure of all components of the winding apparatus, e.g. Failure Modes Effect Analysis (FMEA), Fault Tree Analysis (FTA), Event Tree analysis (ETA), Quantitative Risk Assessment (QRA) etc.

f) A design operational risk assessment on the use of the winding system in the mine. The risk assessment must include: commissioning, operation, examination and testing, maintenance, winch control, communication, competencies, training and emergency procedures.

g) Details of the commissioning process.

NOTE:

1. This process will be required to be repeated every 5 years maximum.

2. An opportunity for witnessing by DPI mechanical and electrical engineering officers must be provided, refer clause 2.3 of MDG 33.

3. Should include; static load testing of the conveyance and winding apparatus, static and dynamic brake testing, control function verification (safety devices, limit switches, etc.).

h) Additional documentation may be requested depending on the documentation submitted.

Note: Safety files to be kept and maintained on the powered winding system

3.2.1.2 Electrical Documents for assessment

All documents, as specified in part 6 shall be provided with the design registration application for electrical assessment.




3.2.2 Winder Types

Modern Drift Winder Assembled Personnel Riding Conveyances

Modern Drift Winder Haulage Engine

TOWER MOUNTED FRICTION WINDER




Ground Mounted Friction Winder

Vertical shaft winder

Vertical Shaft Double Drum Winder

Ground mounted drum winder



3.3 DESIGN REGISTRATION REQUIREMENTS

A summary of design registration requirements is provided in Appendix C

3.4 LOADS

3.4.1 Loads and Powers

When designing components for the winder system, the winder loads shall be established first. The method of determining the loads and torques will vary depending on the type of winder, however the principles remain the same.

3.4.2 Load and Torque

Some loads, such as the material mass, or the skip/conveyance mass, remain constant. Other loads will vary depending on the depth of wind, deceleration rates, or acceleration rates. Frictional and windage forces shall also be considered.

The winder design shall also take into account the shaft configuration requirements, such as depth of shaft and conveyance mass.

3.4.3 Load Cycles

The decision on the winder capacity for production winding will depend on the mine requirement, and will normally be selected on the basis of a required "Tonnes per Hour" of operating time. Having established the Tonnes per Hour required, the engineer can design the winder to output this quantity of product.

When designing for production (bulk) winding the aim should be to lift as large a net load as possible for a given output. This will keep rope speeds and accelerations as low as possible and therefore reduce peak loads and the RMS power required to operate the winder.

For man riding winding, the design of the winder will be governed by the number of personnel which the winder will be required to transport, the size of the shaft, and the time requirements for transportation. Man riding winders vary greatly in capacity, from just a few personnel to up to more than one hundred in single or multideck cages.

For drift winding of personnel and/or materials, the size of the winder will be governed by the maximum materials load required to be transported to the drift bottom. The advantage and usual purpose of a drift winding is to transport large machinery to underground seams without having to dismantle it. Winders can be designed to have an "End of Rope" capacity of from 40 to 100 plus Tonnes. The drift winder is also designed to transport personnel to and from the surface. It is not unusual to transport up to 140 persons at a time in rail mounted conveyances.

Winder duty cycles shall be determined in all cases. The duty cycles will relate the speed and torque at specific stages of the wind, to time. This exercise shall be carried out for all variations of the winding requirements including heavy and light loads.

3.5 WINDING SPEEDS AND ACCELERATIONS

Winding speeds and accelerations can vary enormously from winder to winder. The acceptable ranges of speeds and accelerations which are suitable for winding are given in this Clause. The winder shall be within these ranges unless employing specific and expert advice and a risk assessment shows no additional risk is created.

Winding speeds and accelerations for bulk winding can be relatively high. Speeds up to 15 metres/second are common in deep shafts of up to 1000 metres. For shafts of lesser depth winding speeds may decrease. Decelerations and accelerations of around 0.75 to 1.5 metres/sec2 are common. The designer should consider personnel riding requirements where personnel riding cages are fitted to skips.


Where the use of a conveyance includes transport of personnel, speeds and accelerations shall be consistent with the comfortable transporting of personnel. Winding speeds of 4 to 6 metres/sec are common for shafts up to 500 metres. As shafts become deeper, speeds may be increased. Normal motor control should keep decelerations and accelerations in the range 0.5 to 0.75 metres/sec2.

The safe speed for drift winders depends largely on the condition of the rail track. Contemporary drift haulages are located in drifts having a drift slope of around 1 in 3.5. Steeper slopes and unsuitable brakes on transport conveyances have created problems stopping the conveyances in cases of runaway.

Drift haulage speeds suitable for well maintained track are 3 to 4 metres/second for personnel riding, and up to 2 metres/second for heavy materials winding.

Accelerations and decelerations for drift winders shall be no more than 0.75 metres/sec2 on the drift, and no more than 0.5 metres/sec2 on the turnout.

3.6 ROPE SELECTION

When designing a winding system, the rope size shall be established first. This will be an iterative process and will depend on the “End of Rope” mass. Until final designs are settled, the mass of the conveyance and attachments may be estimated. Use the required Factors of Safety to determine the rope size and thus the mass of the rope. Once the rope size has been selected, attachment masses can be estimated. Estimations for cage and skip masses may be obtained from previous jobs, from manufacturers, or from experience.




Example 3.5.1 Rope Selection

A vertical single drum winder is required to carry 20 persons from the surface to an underground seam located at 400 metres deep. Select a rope suitable for the winder.

Mass of a miner and equipment = 120 Kg

Factor of Safety required on rope

= 10

Mass of personnel in cage = 20×120

= 2400 Kg

Estimated cage = 4000 Kg

Estimated attachments mass = 200 Kg

Estimated rope mass (5 Kg/m)

=(400+15)×5

= 2075 Kg

Mass on rope at drum =8675 Kg

= 8675×9.81

1000

= 85.1 kN

Minimum rope breaking strain = 85.1.8×10

= 851kN

For shaft over 400 m deep use Non-rotating rope

(Ref section 2.3.1)

From AS1426 Steel wire ropes for mines select ø36 Gd 1770 Non-rotating rope. Breaking Strain 891 kN Mass 5.49 kg/m.

Recalculate with actual rope mass

Rope Mass

=(400+15)×5.49

= 2278.35 Kg

Total static load at drum = 8878.35×9.81

1000

= 87.09 kN

Rope Factor of Safety = 891

87.09

= 10.02 > 10

NOTE: This rope selection will be a preliminary only selection. It needs to be rechecked when cage and attachment masses are finalised.

Example 3.5.2 Drum Parameters Selection

For a vertical single drum winder with a surface to underground seam depth of 400 metres, select the drum dimensions necessary to correctly coil and store the rope. Assume a rope diameter of 36mm Assume a rope angle from drum to sheave of 45 Assume the drum will have parallel rope grooves. From Section 3.9.6 Fleet angle required Distance from drum to sheave Therefore Drum Width = 2×(Distance to sheave×Tan 1.5) = 2× 17× Tan1.5× 1000 Drum to Rope Ratio (Section 3.9.3.1) Therefore Minimum Drum Diameter Pitch of rope groove (Section 3.9.3.5) Therefore Number grooves

say

= 1.5 = 17 m = 890.4 mm = 70 = 70×36 = 2520mm = 36 + 36×0.04 = 37.44 mm

37.44 = 23.78 = 24 grooves

Therefore Drum width Actual fleet angle

= 24×37.44 = 898.56 mm = Tan-1

(449.28/17000) = 1.514

Allow 3 dead coils on drum at all times Working rope Dia = 2520 + 36 Working rope length = (24-3)××2.556 1st Layer = 2556 mm 1st Layer = 168.63 Metres Working rope Dia 2nd Layer

= 2556 + 2×30.75 = 2617.5 mm

Working rope length 2nd Layer

= 23 × × 2.6175 = 189.13 Metres

Working rope Dia = 2617.5+2×30.75 Working rope length = 24××2.679 3rd Layer = 2679 mm 3rd Layer =201.99 Total drum capacity with 3 Layers

Capacity required = 559.75 metres = 400+50 = 450 metres < 559.75



3.7 TORQUE

The power and torque for a drum winder can be developed from the following requirements. The torque shall be able to:

(a) lift/lower the load at constant speed

(b) accelerate the load and system at a nominated acceleration rate

(c) decelerate the load and system at a nominated deceleration rate

(d) overcome frictional resistances.

When considering these torque and power requirements, keep in mind the following:

As the “End of Rope” load is lowered or raised, the rope mass creating torque at the drum will increase/decrease due to the change of mass of rope hanging from the sheave.

However, since the overall rope length is constant, the accelerating/decelerating torque due to the inertia of the rope will be constant.

Friction resistances are expressed as:

(i) Torque to overcome rope friction

(ii) Torque to overcome shaft friction.

Values for friction have been derived over the years by various methods including friction formulae. However the best source of friction values is found from experience. As a guide the following values may be used:

Winder Type Rope Friction Shaft Friction

Vertical winding with rope guides

Vertical winding with wooden shaft guides

Drift haulage winding with good drift tracks

= 0.05

= 0.05

= 0.03

= 0.13

= 0.15

= 0.06

3.8 INERTIA

3.8.1 General

To calculate the torque required for accelerating or decelerating the load and system, calculate the system inertias first.

Inertia is the resistance of a body to being moved. Rotational inertia is the resistance of rotating bodies such as drums, gears, head sheaves to being accelerated or decelerated (braked). Rotational inertia, also known as the Polar moment of Inertia, Jm, has the dimensional units Kg m² and the general equation Jm = mjrj²

To accelerate the winding system, a portion of the supplied torque will be needed to overcome the components’ resistance to movement.

The polar moments of inertia are related to the mass and shape of the moving parts. To calculate the inertia for a component, such as the winder drum, the component is broken down into smaller parts, or segments and the segment inertia calculated. The summation of the individual segments becomes the inertia for the component.

In winder system design, the inertia shall be referred to the drum shaft in order to establish the torque at the driving shaft.


The values for the various shapes required to establish component inertia can be found in standard texts or Machinery’s Handbook. Some values will be taken directly from manufacturers’ catalogues (such as for gearboxes, couplings, motors). The designer should ensure that the units being used are the same.

Components not directly associated with the drum axis should have the inertia referred to the drum shaft. Inertias of linear moving masses will have an equivalent inertia referred to the drum shaft.

3.8.2 shaft loads

Shaft Loads include ropes, skips, cage, attachments, and similar.

To convert linear inertia of shaft loads to rotational inertia seen by the drum:

Inertia at Drum Shaft = Mass × Drum Radius²

3.8.3 Head sheaves

Inertia at Drum Shaft = Head sheave inertia × ((Drum Dia)/(Sheave Dia)²

3.8.4 Motor armature

Inertia at drum = Motor Inertia × gear ratio²

3.8.5 Gearbox

Gearbox inertia is normally given by the gearbox manufacturer as the inertia at the input shaft.

Inertia at Drum Shaft = Inertia Gearbox (Input) × Gear ratio2.




Example 3.4.3 Polar Moment of Inertia

A winder drum has been designed for a single drum winder carrying personnel to a seam depth of 400 metres. Find the Polar Moment of Inertia for the drum. Fig. 4.4 shows a cross section of the drum.

DRAFTING NOTE: change unit for “metres” above to lower case.

3.9 ACCELERATING AND DECELERATING TORQUE

3.9.1 general

Having calculated or otherwise obtained the system inertia at the drum shaft, the following formula shall be used to find the torque required to overcome the rotational inertias:

T = Jm

where: T is torque in Nm

Jm is rotational inertia in Kg.m2

is angular acceleration in radians/second2

Where the required acceleration for the winder is given at the conveyance in units of metres/second2, the units shall be converted to angular acceleration or deceleration at the drum rope PCD.

(Radians/sec2) = Linear Acceleration × 2 (metres/sec2)

Rope PCD

3.9.2 Static Torque

Static torque is that torque required to hold the load stationary at a nominated depth, ignoring frictional resistances.

3.9.3 For vertical shafts

T = Mass (Kg) × 9.81 × Drum Radius (m)

1000

where T is torque in kN.m.

3.9.4 For inclined shafts (drifts)

T = Mass (in Kg) × 9.81 × Sin(Gradient angle) × Drum Radius (in m)

1000

where T is torque in kN.m.

3.9.5 Accelerating or Decelerating Torque

The torque required at the drum shaft to accelerate or decelerate the winder system will be the summation of the various torques created by inertias, frictional resistances, and static torques.

Total Torque = Static Torque + Inertial Torque + Torque from friction.

To be on the safe side when considering the braking requirements of winders, frictional resistances should be ignored, because frictional resistances vary and so cannot be relied upon.



Example 3.4.4 Calculate torque to accelerate system

A vertical winder has components with the following calculated moments of inertia and masses. Find the system inertia and the torque required to accelerate the system when the conveyance is at the bottom on the shaft. Assume a gearbox ratio of 40.16:1 and a maximum acceleration rate of 1.5 m/s2.

Component Component

Inertia Kg m2

Component Mass

Kg

Inertia referred to Drum Shaft Kg m2

Drum

Drum Shaft

LS Coupling

Gearbox

HS Coupling

HS Brake

Motor

Headsheave

Cage

Rope

Payload

10017.5

1.6

9.3

0.15

3.5

5.2

35.0

2500.0

4200

2278

1760

= 10017.5

= 1.6

= 9.3

0.15×40.162 = 241.92

3.5×40.162 = 5644.89

5.2×40.162 = 8386.7

35×40.162 = 56449

2500×(2520/2000)2 =3969

2278×(2.52/2)2 =3616.6

4200×(2.52/2)2 =6667.9

1760×(2.52/2)2 =2794.17

J = mk2 = 97789.6 Kg m2

Angular acceleration at drum = linear acceleration × 2

Drum diameter

= 1.5 × 2

2.52

= 1.1905 Radians/second2

Additional torque to accelerate = J

= 97789.6 × 1.1905

= 116429.2 Nm

= 116.43 kNm

Static torque at shaft bottom = static load × drum radius

= 80.82 × 2.52/2

= 101.84 kNm

Torque to overcome friction = static torque × friction coeff.

= 101.84 × .18

= 18.33 kNm


Total torque to accelerate =116.43 + 101.84 + 18.33

= 236.6 kNm

3.10 WINDER DRUM DESIGN

3.10.1 function

For drum winders, the purpose of the winder drum is to accommodate the winding rope, together with any excess or testing lengths. It also provides a secure anchorage for the rope and allows the rope to scroll correctly on the drum.

For friction winders, the winder drum accommodates driving elements, wedged and bolted to the periphery to drive the winding rope(s) by frictional force from contact with the driving elements.

3.10.2 General Construction of Winder Drums

A current acceptable practice is to fabricate the winder drum using rolled steel plates for the shell. Such drums have flexible end connections in comparison with rigid end connections (with much stiffening) used in older drum construction.

Fabricated drums are normally in mild steel plate. Plates shall be certified free from laminations and inclusions. Any inclusions present at the time of rolling are likely to become laminations during rolling, and the plate could be rejected after much of the work has been done.

Before any machining commences the fabricated drum should be stress relieved and all major welds ultrasonically proved.

The brake disc path may be welded or bolted to the drum. Both methods have been successfully used. Currently drum design favours the bolted-on approach.

The brake disc material should be Grade 350 steel. Other steels of equivalent or greater hardness may be used, depending on the brake forces and thermal requirements of the brake system.

Give special attention to the shell-to-endplate connection and the method used for welding. The connection shall be flexible enough to avoid weld cracking.

3.10.3 Design Methods for Drums

Use an acceptable stress analysis method to calculate drum design stresses. A procedure known as the Atkinson and Taylor method has been successfully used to design many winder drums using flexible endplate practice.

For Grade 250 steel, a maximum shell compressive stress of 150 MPa should not be exceeded.

For Grade 250 steel, bending stresses in the shell should not exceed 40 MPa, and bending stresses in the end plates 60 MPa.

3.10.4 Winding Drum Construction

Winding drums should be constructed to provide storage for the rope, and to ensure that the rope safely and correctly coils onto and uncoils from the drum.

The correct Drum to rope ratio (D/d Ratio) will depend on the rope speed, wire tensile strength and rope construction. For rope speeds up to 6 Metres/second a minimum D/d ratio of 70:1 is a good guide for most winding drums using flattened strand rope. For locked coil rope, a D/d ratio of 100:1 should be used.



The correct fleet angle from the winding drum to the head sheave should be maintained. For grooved drums this angle should be a maximum of 1.5 degrees and a minimum of 0.25 degrees. This provision is to ensure the rope will scroll away from the drum flange.

NOTE: The fleet angle is the angle formed between a line from the centre of the drum to the centre of the head sheave and a line from the drum rope flange to the centre of the head sheave. (See Fig 4.5).

For permanent drum winders the drum shell should be grooved to suit the rope. For rope speeds up to 6 metres/second parallel grooving with a rope cross-over section is recommended.

The drum/rope anchor attachment shall be readily accessible for routine inspections.

A harmonic analysis should be carried out to ensure that fundamental vibrations do not coincide with the rope/drum crossover frequency.

Parallel rope grooves should have a pitch spacing of Nominal Rope Diameter plus 4%.

Parallel rope grooves should have a groove radius of Nominal Radius of Rope plus 5%.

Parallel rope grooves should have a groove depth of no more than 10% of the rope diameter.

For parallel grooved drums the rope cross-over section should be machined to the bottom of the grooves for a length of not less than 20 times the rope diameter.

To ensure the rope is protected from nicks, all sharp edges should be carefully removed.

3.10.5 Rope Flanges

The rope flange height should be a minimum of the fully wound rope depth plus two and a half (2.5) full rope diameters. This is to ensure that, should two coils pile up on the drum flange, they will not fall off.

3.10.6 Rope over Coiling Protection

To ensure that the rope always scrolls correctly, the drum should be fitted with a device that stops the winder (by emergency braking) if the coils do not scroll back from the drum flanges. This device is usually a beam located across the drum, which operates a switching device should the rope coil above its maximum number of layers.


Rope over Coiling Device

Older Spoked Stiff Winder Drum Design




Flexible Fabricated Drum Design

3.10.7 Rope Fleet Angles

The width of the drum between the rope flanges will be governed by the required fleet angle to give correct scrolling of the rope. Excessive fleet angle results in abrasion of the rope and of the rope grooves. Insufficient angle may lead to the rope over coiling against the rope flanges.

For grooved drums and triangular strand or non-spin ropes, the fleet angle should not exceed 2 degrees and an angle of 1.5 degrees is a good working angle.

For ungrooved drums, the maximum fleet angle shall be 1.5 degrees.

In the case of locked coil ropes the fleet angle should not exceed 1 degree 20 minutes (1.33 degrees).

3.10.8 Hawse Hole or Rope Entry Position

The rope is passed from the rope anchorage position, usually inside the drum endplate, to the first coil through a hole formed in the drum shell and known as the hawse hole. It is important that the correct position and side of the drum be determined for the hawse hole.

Where the centre of the sheave falls to one side of the drum rather than on the centerline of it, the hawse hole on that side should be used, irrespective of what hand of lay the rope is. The arrangement should also be such that the number of unused turns of rope on the drum is sufficient to cause the live turns of rope to always be on the side of the drum beyond the sheave centreline with respect to the hawse hole in use.

Hawse holes shall be designed so that the rope enters the drum without sharp turns. Corners and sharp edges shall be removed to avoid damage to the rope by nicking or crushing.

3.10.9 Wedges and Risers

To avoid abrasion of the rope on its first turn, a steel rope wedge shall be fitted against the flange in front of the hawse hole. When the rope fills the first layer and starts to return on the second layer, the rope will be lifted. At this point severe crushing can occur. To prevent this, a steel riser shall be fitted to the flange and drum shell to lift the rope.

Wedges and risers should be approximately 20 rope diameters long.




Courtesy Haggie Steel Ropes Limited

3.10.10 Rope Vibrations

Transverse vibrations or oscillation of the rope between the headsheave and the drum is a problem sometimes encountered on drum winders when operating with multi-layers of rope. These oscillations may occur during some part of the winding cycle. These oscillations should be checked in the design stage, since they are difficult to overcome once the winder is in place.

The frequency of the fundamental vibrations may be measured from

= 1 F

2Lc m

where = fundamental frequency in cycles/sec

Lc = distance from headsheave to drum in metres

F = tension in rope in kN

m = mass per unit length of rope in kilograms/metre

Ensure that the impulses from the turn cross-over on the drum do not coincide with the fundamental frequency of the rope. Second and third harmonics should also be checked where higher rope speeds are being used.

Drum Shaft Attachment - Keyed Arrangement




Drum Shaft Attachment - Bolted arrangement

3.11 SHAFT DESIGN

3.11.1 Fatigue

Shaft design for winder drums shall accord with AS1403 - Design of Rotating Steel Shafts for Fatigue. The maximum acceleration or braking loads shall be used.

In shaft design, torque, bending moments, and axial loads, and any combination of loads shall be examined. All loads should be considered, including normal working, accelerating, braking, heavy materials, erection, and special heavy lift loads.

A fatigue factor of 1.3 shall be used when designing the shaft.

The shaft material should be 1040 or 1045 grade steel. This provides an economical shaft with good fatigue and machining properties. Steels having higher tensile properties may be used, however, unless designing for strength, there is little economic or engineering gain.

The shaft should be designed on the maximum peak loads calculated from acceleration and braking loads, as defined by AS1403. Consideration shall be given to using a cumulative fatigue damage calculation to determine the effects of a small number of heavy loads on the fatigue life of the shaft.

Shafts shall be checked for deflections to confirm that bearing selection is within deflection tolerances. High speed shafts shall be designed to ensure vibrations are kept within limits.

3.11.2 Strength

Check shafts for strength. The winder shaft should resist the breaking strain of the rope plus 20% without permanent deformation.

3.11.3 Bearings

Select shaft bearings using good bearing selection procedure.

Calculate bearing life based on the life of the winder using a safety factor that ensures overall system reliability.

To minimise fatigue problems check bearing housings, housing caps and housing hold down bolts for strength, using the minimum rope break strength plus 20% without failure.

Coupling end shaft connection for 80 Tonne Drift Haulage




Non-Coupling end of drum shaft for 80 Tonne drift haulage

Wherever possible use four (4) housing bolts and cap screws. Bolt and cap screw tightening torques shall be recorded and correctly implemented.

3.11.4 Shaft to Drum Connection

Where possible, avoid using keys to connect shafts to drums; bolted connections should be used. When keys are used, check them for both fatigue and strength.

Keys fitted to winder shafts should be a tight side fit to avoid fretting caused by any inertial movements of masses.

3.12 GEARS, GEARBOXES AND COUPLINGS

Using gears and/or gearboxes in the winder drive system is a common method of speed reduction/torque increase for the winder drum. Some large winder designs, however, eliminate the gearbox or gears and couple the motor armature directly to the drum shaft. Technological advances also allow the armature to be built inside the drum.

3.12.1 Selection of Gearboxes

Ratings of gearboxes for use with drum winders shall be based on both fatigue and strength.

The fatigue and strength ratings selected for gearboxes or gears shall be based on both the cumulative fatigue damage analysis that takes into account all load cycles, including any heavy lift or abnormal load conditions and the maximum peak loading due to acceleration or braking.

The service factor for durability for winder gears and gearboxes should be a minimum of 1.5.

The service factor for strength for winder gears and gearboxes should be a minimum of 1.75.

Select a service life of 40 years as a minimum for winder gears and gearboxes.

Give special consideration to the thermal rating of hardened and ground gearboxes. Where possible, gearboxes should be sized to avoid using external cooling systems.

3.12.2 Gearbox Monitoring

Real Time gearbox monitoring is recommended for automatic winders. Sensors should be used to monitor:

(a) High lubricating oil temperature

(b) Low lubricating oil level

(c) High bearing temperature

(d) Vibration

3.12.3 Bull Gears and Pinions

When bull gears and pinions are used as the final reduction drive gears, service factors for fatigue should be 1.5 minimum. Service factor for strength should be a minimum of 1.75.

Adequately seal gears and pinions to prevent lubrication splash and contamination of brake discs.

Shaft sections of the gear pinions should have sufficient strength to resist rope break plus 20% without failure.

Select bearing housings, caps and bolts to resist rope break plus 20% without failure.

3.12.4 Manual Gear Reduction

Gearboxes with manual gear changing shall not be used.

Example 3.5 - Selection of a gearbox for winder duty

Calculate the values for the Torque-Speed-Time duty cycle for a single drum winder winding to a seam depth of 400 metres with a load of 20 persons. Assume 40 cycles per day for a 7 day per week operation over a period of 40 years. Assume an acceleration and deceleration rate of 1.5 metres/second2 and a maximum speed of 4 metres/sec. The conveyance will creep out of and into the fixed guides at 1 metre/second for a distance of 5 metres.

Values for each section of the cycle will be calculated and presented in a table as follows:

Descending Section 1 Acceleration Section 2 Const. Speed Section 3 Acceleration Section 4 Const. Speed Section 5 Deceleration Section 6 Const. Speed Section 7 Deceleration

Drum RPM 0 7.58 7.58 7.58 7.58 30.31 30.31 30.31 30.31 7.58 7.58 7.58 7.58 0

Time (Sec) 0 0.667 5.667 7.667 101.835 103.835 108.835 109.502

Distance (m) 0.33 5.33 10.33 389.67 394.67 399.67 400.00

Torque (kNm) 41.75 41.72 93.04 93.38 41.38 41.04 93.72 119.46 235.89 236.23 119.80 120.14 236.56 236.60

Total Hours 108.20 811.12 324.45 15276.28 324.45 811.12 108.20



Ascending Section 8 Acceleration Section 9 Const. Speed Section 10 Acceleration Section 11 Const. Speed Section 12 Deceleration Section 13 Const. Speed Section 14 Deceleration

0 7.58 7.58 7.58 7.58 30.31 30.31 30.31 30.31 7.58 7.58 7.58 7.58 0

0 5.667 7.667 101.835 103.835 108.835 109.502

0.35 5.33 10.33 389.67 394.67 399.67 400.00

236.60 236.56 120.14 119.79 236.23 235.89 119.46 93.72 41.04 41.38 93.38 93.04 41.72 41.75

108.20 811.12 324.45 15276.28 324.45 811.12 108.20

= 219 Sec = 35527 Hrs

Total hours @ 40 cycles/day for 40 years = 40 × 219 × 40 × 365 / 3600

= 35527 Hours (continuous life)


Example 3.5 (Continued)

The duty cycle for the winder may be presented with the Torque-Speed-Time graphs taken from the previous table. Selection of the gearbox can now be based on a cumulative fatigue damage calculation. For a commercial gearbox, the gearbox rating is normally given with a life rating of 20000 hours with a service factor of 1. An equivalent torque rating can be obtained from table Ex 4.5 for 20000 hours equivalent life.

Equivalent life Design Torque and Speed analysis Component reference: Selection of gearbox Data for cumulative fatigue analysis -

Step No Total Time Speed In Speed Out Torque In

Torque Out

Hours RPM RPM kNm kNm

1 108.2 0 7.58 41.75 41.725

2 811.12 7.58 7.58 93.04 93.38

3 324.45 7.58 30.31 41.38 41.04

4 15276.28 30.31 30.31 93.72 119.46

5 324.45 30.31 7.58 235.89 236.23

6 811.12 7.58 7.58 119.8 120.14

7 108.2 7.58 0 236.56 236.6

8 108.2 0 7.58 236.6 236.56

9 811.12 7.58 7.58 120.14 119.79

10 324.45 7.58 30.31 236.23 235.89

11 15276.28 30.31 30.31 119.46 93.72

12 324.45 30.31 7.58 41.04 41.38

13 811.12 7.58 7.58 93.38 93.04

14 108.2 7.58 0 41.72 41.75 S-N slope index P for component material 3.5 Analysis output - Design torque = 129.307 kNm Design speed = 30.31 RPM Design hours = 20000 Design KW = 410.397 (Cumulative fatigue calculation courtesy MECH-PAK software)



Gearbox rating

Durability = 410.4 × 1.5

= 615.6 kW with Service factor 1.

Strength = 410.4 × 1.75

= 718.2 kW with Service Factor 1.75

Peak Torque = 236.6 × 2

= 473.2 kN.m with Safety Factor 2

3.13 CLUTCHES

The normal method of changing levels for double drum winding is to de-clutch one drum and turn the de-clutched drum to relocate the conveyance to a different level. This is achieved with a toothed clutch. The clutch housing is attached to the winder drum. The clutch body slides on the shaft. When considering clutches associated with winders, this is the main purpose of the clutch; however other component areas such as gearbox clutches may also be required. The standard clutch design principles apply to all toothed clutches.

3.13.1 Clutch Design

The clutch shall be designed to good engineering clutch design principles. Winder clutches are normally designed using involute or straight splines. Where involute splines are used, the standard DP (Inch) or Module (Metric) system shall be adopted.

3.13.1.1 Interlocking of clutches and brakes

Before the winder drums can be declutched, the drum brakes on the declutched drum shall be positively locked on.

3.13.1.2 Clutch Factors of Safety

If a winder drum clutch fails, the winder drum brake shall be the means of arresting the conveyance. Drum brakes shall be activated by the drum overspeed and broken shaft control system which shall be independent of a clutch failure. Therefore the factors of safety required for the clutch should regarded as being the same as those required for the shaft, i.e. 1.3 on fatigue rating and a minimum of 2 on strength.

3.13.1.3 Commercial Clutches

Where a commercial clutch unit is to be used, the clutch should use a service factor of 2.0 for vertical winders and 1.75 for drift winders. In all cases the strength of the clutch should be checked against the worst possible load.


Photographs - Double Drum Shaft Winder

3.14 BRAKE CALIPERS AND BRAKE SUPPORTS

Drum winders built relatively recently use disc brake calipers in single or multiple units acting on a brake disc which is attached directly to the drum by a bolted or welded connection. Older winders have various configurations of brake paths, posts, and brake




components. In all cases the brake shall apply a braking torque to the drum, and hence the rope, to stop the conveyance and winder system in a controlled manner within the requirements of the guideline.

3.14.1 Calculation of Braking Torque

Various texts are available on brake torque calculation. The brake torque calculations should be supported by available literature on the frictional and thermal properties of the brake lining material being used. Factors of safety for brake components should be a minimum of 10 except screwed threads. A minimum F.O.S. of 15 based on the root diameter of the thread shall apply. Post caliper brakes shall act in both directions.

3.14.2 Band Brakes

Band brakes are unacceptable for drum winders and shall not be used.

Multiple disc brake calipers on 80 Tonne drift haulage

3.15 HANDRAILS, GUARDS, LADDERS AND STAIRWAYS

3.15.1 general

All equipment, machinery, moving components, and similar supplied as component parts or as complete units, when finally commissioned and ready for service, shall be provided with adequate guards, railing and fences, ladders, platforms and stairways, to ensure the protection of operators, service personnel, inspectors, and any other person involved in the operation and maintenance of the winder, haulage or associated equipment.

References: AS 4024.1-2006 Safe Guarding of Machinery

AS 1657 Fixed platforms, walkways, stairways and ladders

3.15.2 Design Principles

The following principles shall be observed in the design of all guards and fences.

(a) Guards shall be designed and positioned, so far as is reasonably practicable, to protect personnel from hazard.

(b) Guards shall be designed to take into account the practical considerations that will arise in service.

(c) To maintain observation and ventilation, guards should be made of a mesh material, suitably protected at the edges. However in some cases a solid guard may be preferable.

(d) Guards shall be provided with sufficient joints or other features to facilitate initial installation and subsequent maintenance operations.

(e) Where practicable the design shall enable safe lubrication without removing the guard. Where this is impracticable, arrangements shall be made to ensure that lubrication can be achieved without danger (e.g. for the machinery to be stopped and isolated).

(f) Where it is necessary to carry out routine adjustments with machinery in motion, the design shall allow for this without the need to remove the guard.

(g) Guards shall be designed so that individual sections have adequate strength and stiffness for transporting and installing, and when in use are sufficiently robust to retain their shape and designed clearance from moving parts. This may be achieved either by using mesh or plate of adequate inherent stiffness, or by using lighter mesh or plate with suitable additional stiffening.

(h) All metallic guards shall be protected against corrosion to a standard appropriate for the application.

(i) Where sheet metal is used it shall be a minimum thickness of 1.5mm. Adequate ventilation shall be provided.

3.16 FOUNDATIONS

3.16.1 Foundation design

Foundation design for winder drums, associated machinery, headframes and headsheave supports, and rope roller supports including crest and side guide or turnout roller support structures should be undertaken, and/or checked by a competent civil design engineer.

A complete set of foundation calculations and drawings, certified by a person accredited to do so, should be provided for the colliery record system.

The foundation design shall be carried out to the current relevant Australian Standard civil and structural codes.

3.16.2 Headframe, guide and arrester systems

Headframe, guide systems and arrester system foundation design shall note the requirements of AS 3785 Parts 1 to 8.

For single rope drum winders and for drift winders, the foundations for drums and head sheaves shall allow for the maximum rope break condition plus 20% without failure of either the concrete or steel support structure. For this condition failure means "no longer able to be used to support the winder working loads".

For all drum winders, foundation bolts shall be capable of resisting all fatigue loading cycles, and shall consider the maximum rope break condition plus 20% without permanent



failure. For this condition failure means "no longer able to support the winder working loads".

3.16.3 Foundation bolts

All foundations shall use multiple foundation bolts to transmit loads to mass concrete.

Bolt calculations for both fatigue loadings and rope break or strength loadings shall be included in the foundation calculations.

Bolt tightening torques shall be included in the calculations. Foundation design should consider maximum bolt loadings transmitted to the mass concrete by bolt tightening to a maximum torque of 0.65 × proof stress of bolt material.



3.17 HEADSHEAVES

The general requirements for heads sheaves used for drum winders are compiled in AS 3785 Part 7 - 1993 for the sheave, sheave shaft and bearings.

3.17.1 Calculations

Appendix A of AS 3785.7 gives constructional proportions for rim sections for both plain rims and rims with inserts. Calculations should substantiate the use of these dimensions.

Design calculations shall be provided for both fatigue and strength considerations. Strength calculations shall assess the rope break condition and shall evaluate the rope forces at rope break condition plus 20% without failure of any sheave assembly component. For this condition failure means "no longer able to support the winder working loads".

3.17.2 Head sheave support bolts and structure

Head sheave support bolts and the support structure design should encompass the fatigue loads and the rope breaking loads.

When calculating stresses in the sheave components, stresses shall be based on the maximum worn condition for the head sheave rim.

3.17.3 Wheel Diameter to Rope Ratio

For all headsheaves, the wheel to rope diameter ratio should be checked with the rope manufacturer to ensure final suitability.

In general the sheave wheel diameter to rope diameter ratio is the same as that required for the drum.

In the case of sheaves for vertical drum winders using triangular stand ropes, usual D/d ratios range from 70:1 to 100:1.

In drift haulage winders where the angle of wrap is low, the wheel to rope diameter ratio may be as low as 50:1 for triangular strand ropes.


Older Style Spoked Headsheave

Fabricated and Machined Headsheave




Headsheave Installation - Shaft winder

Headsheave Installation - Drift Winder

Headsheave Installation – Ground Mounted Friction Winder

3.17.4 Sheave Wheel materials

Materials for the wheel construction will depend on the type of manufacture. Sheave wheels may be cast in either steel or meehanite (or SG iron) or be fabricated from rolled steel and flat plate. Grey cast iron is not considered suitable for sheave wheels and shall be avoided.

See AS 3785.7 for the testing of sheave materials.

The most appropriate material for sheave wheel shafts is Grade 1040 or 1045 steel. Little economical or engineering advantage is gained by using higher tensile grades of steel.

3.17.5 Headsheave Wheel Construction

The headsheave wheel construction may vary with the type of duty required.

Flat plate construction consists of a profiled circular steel plate with the rope groove machined in the outer circumference. The wheel may be lightened to reduce inertia by profile cutting the web area to form spokes or lightening holes. Bosses are added to build up the hub to provide stability and reduce shaft stresses. Where welding processes are used, the sheave should be stress relieved. These sheaves are used for slow speed, non-production requirements such as stage winders.

Cycle spoke type headsheaves consist of a cast rim and hub with steel bars integrally cast into the hub and rim to form spokes. This type of wheel has been popular for production winding for many years due to its low inertia.

Cast meehanite or cast steel construction wheels may be either single piece or split halves which are machined, keyed and bolted together. Split type sheaves are used when large diameter sheave size becomes a transport problem.



Fabricated sheave wheels using a combination of a cast rim and hub and cold rolled steel section for the spokes are common.

3.17.6 Headsheave Design

Headsheave design is in three sections: the wheel, the shaft and the hub. AS3785.7-2006 covers many of the design requirements.

The static design load should be the design rope break load (the rope break load × 1.2). This should include the effects of the fleet angle.

For static design the combined stress should not exceed 0.9 × yield stress.

For static design the combined buckling stress should not exceed 0.9 times the Euler buckling stress for components in compression.

For fatigue design assess the effects of the fleet angle and groove misalignment, with along any dynamic or vibrational loadings.

Calculate the maximum allowable fatigue stress using a rational analysis method (e.g. Goodman diagram) and allowing a fatigue reserve factor of 1.3.

The bearing stress between the rope and the rim groove at the maximum working load should not be greater than 3.1 MPa. A general figure of 2 MPa is often used.

See AS3785.7-2006 for the required shaft design. Limit shaft deflection to 1 in 2000 at the maximum working load.

See AS3785.7-2006 for bearing design and life requirements.

3.18 MANUFACTURE AND INSTALLATION

3.18.1 Manufacture

Components comprising the powered winding system shall be manufactured to the designs and tolerances specified on the detail drawings.

3.18.2 Materials

Steel structures shall be manufactured from materials specified in AS 3990 or AS 4100. Steels, which do not comply with AS 3990 or AS 4100, may be used when the mechanical properties, chemical composition and weldability (if applicable) are verified by test to be suitable for the application.

3.18.3 Testing

Where items are required to be subjected to testing for certification purposes, the manufacturer shall advise the testing criteria, provide access for witnessing the test procedure, obtain a proof test certificate for the item and include all documentation with the supply of the item or apparatus.

3.18.4 Welding

All welding and testing shall be carried out in accordance with AS 1554.1, AS 1554.4 or AS 1554.5, as applicable.

3.18.5 Erection

Structural steel shall be assembled according to the designs and match markings specified on the detail drawings.

Structures shall be plumb and bolted connections shall be tightened to the specified torque for the size and type of bolt in the connection.


3.18.6 Installation

The winder components shall be installed in the structures

3.18.7 Adjustment

Structures shall be adjusted to accept the movement of the components that comprise the powered winding system.

3.19 COMMISSIONING

3.19.1 New or Relocated or Upgraded Winders

3.19.1.1 Testing

Every powered winding system shall be subjected to thorough testing and commissioning of all of the components that are necessary to perform the winding duties.

A detailed testing program shall be prepared and the program shall be assessed to its adequacy by the manufacturer and the purchaser prior to commencing final testing of the winder/haulage system.

To obtain registration for powered winding equipment the new, upgraded, or relocated winder shall be tested at installation:

(a) To the maximum loads and speeds hoisted by the winder;

(b) To the minimum loads and speeds hoisted by the winder;

(c) To any combination of loads and speeds that will put the winder under its worst hoisting duty.

3.19.1.2 Personnel

Testing shall be carried out by:

(a) A competent electrical engineer in co-operation with

(b) A competent mechanical engineer in co-operation with the manufacturer and purchaser representatives.

(c) Department inspectors may witness the commissioning.

3.19.1.3 Records

Test records shall be retained and finalised for:

(a) Submitting with certification and registration documentation

(b) Recording and filing by the purchaser or the mine.

Test records shall define all testing and record the results of such testing of safety equipment, safety equipment settings, brake settings, conveyance stopping distances, deceleration rates, test loads and certification, and any other tests relevant to the winder, or as required by the appropriate Standards and Guidelines.

A copy of the initial “Brake Record of Test”, showing completed entries for initial brake testing, shall be included with the test report.

3.19.1.4 Final testing, certification and registration

Final testing certification and registration shall include the following

(a) Inspect the installation and examine test records, specifications, drawings and design calculations and audit such documentation by an independent examiner, and



(b) Witness all of the tests and impose any further tests as deemed necessary to ensure that the installation operates safely and complies with the Standards and guidelines.

3.19.2 Existing Winders

Existing installed winders should be tested:

(a) When winder maintenance has involved replacement of parts which are components of the safety, brake, or drive systems of the winder;

(b) When brake linings or brake calipers have been replaced;

(c) When ropes, rope cappings, or attachments have been replaced;

(d) As required by the Winder Management Plan for the safe operation of the winder.

(e) Non Destructive Testing of the winder components annually or as required by the Winder Management Plan to accommodate the journeys made by the winder.

Testing shall be carried out by persons authorised by the mine manager or his/her representative, as competent and authorised to perform such testing.

3.19.3 Shaft Sinking Winders

No winder shall be used for shaft sinking, or stage winding, without having first been tested to ensure all safety functions, features, stops, and all brakes, are operating correctly as required.

New shaft sinking winders, stage winders, and winders not previously used for shaft sinking shall be tested to ensure all safety functions, features, stops, and all brakes, are operating correctly as required.

Prior to commencing operation at a new mine site for a re-located shaft sinking winder the winder shall first be Item Registered for that site.

All testing carried out when shaft sinking winders are relocated shall be entered into a book kept specifically for this purpose, and made available to Department Inspectors when requested for examination.

Testing of re-located shaft sinking winders previously used for shaft sinking, and having capacities exceeding, or the same as, those required at the relocated site, shall be carried out by a person authorised by the Mine Manager, or his/her representative, to do so.

Before commencing a new shaft sinking project, the shaft sinking winders, conveyances and associated components, shall be thoroughly examined for cracks, deformations, corrosion, or any other damage which could cause the winders to be unsafe. Non-destructive testing of drums, shafts and brake linkage components should be carried out. A completed inspection report including all tests shall be signed by a competent engineer and filed with the winder records.

No rope shall be used for shaft sinking purposes unless:

(a) It is new, certified, and complies with Section 2 of the guidelines.

(b) Where the rope has been used, for example on previous shaft sinking projects, the rope shall

(i) comply with Part 6 Section 8 of the guidelines,

(ii) be non-destructively tested before re-use and

(iii) examined by a competent person in the area of wire ropes.


The documented history of the rope shall be reviewed before the rope is accepted for re-use.




4 OPERATION

4.1 GENERAL

4.1.1 Risk assessment

Users of mine winder must carry out an operational risk assessment(s) to identify all hazards, assess the risks arising from those hazards and implement appropriate risk controls from the use mine winders. This operational risk assessment must be carried out prior to the mine winder being used on a mine site.


This risk assessment should be reviewed and a new operational risk assessment carried out whenever variations in design, use, conditions or environment could change the risk.

The risk assessment shall include –

a) specific site requirements;

b) site specific hazards;

c) site competencies;

d) develop safe systems of work before normal operation; and

e) consideration to the designers operational risk assessment and the intended use.

4.1.2 Use of Mine winders

Users of mine winders must1 ensure that –

a) The winder is used in accordance with its intended operational envelope and the designers recommendations;

b) The winder is not operated unless the operator is supervised and receives adequate information and training;

c) The winder is only used for the purpose which it was designed, unless a competent persons assesses that the change does not present an increase in risk to safety;

d) safety features are used as intended by the designer of the mine winder;

e) persons do not work in the immediate area of remotely or automatically energised parts of bolting plant without appropriate controls and systems of work in place;

f) measures are provided to prevent unauthorised alterations or use of mine winders;

g) mine winders is subject to appropriate checks, tests and inspections necessary for safety;

h) the winder is withdrawn from operation if there is an immediate risk to safety;

1 Refer clause 136A OHS regulation

and

i) only competent persons make adjustments.


4.1.3 Competencies

The mine management system, in conjunction with the supplier, shall address the minimum acceptable competencies for particular types of work. Such competencies should be –

1. for operators;

2. for maintenance people; and

3. be re-assessed at regular intervals.




5 MAINTENANCE

5.1 GENERAL

The coal operator must2 ensure that in relation to repair and maintenance of mine winders –

a) necessary facilities and systems of work are provided and maintained; and

b) inspections, maintenance and cleaning is carried out with regards to designers, manufacturers information or otherwise developed by a competent person; and

c) all safety features and warning devices on bolting plant are tested and maintained; and

d) competent persons assess any damage to mine winders, where the risk to safety is increased; and

e) repair, inspection and testing is carried out by a competent person; and

f) repairs to mine winder keep the winder within its design limits.

g) if access to the winder is provided, the winder is stopped and a lockout, danger tag, permit or other control measure is used.


5.2 MAINTENANCE

An appropriate examination, inspection, testing and maintenance management system shall be developed and implemented to ensure the mine winder is fit for purpose, safe and without risks to health when properly used.

This system should be developed based on site specific conditions with consideration of the designer’s recommendations or otherwise by a competent person.

2 Refer clause 137 OHS Regulation

APPENDIX A REFERENCES

The following Australian Standards and Guidelines should be used as reference documents for this guideline:

Australian Standards

AS 1403 Design of Rotating Steel Shafts for Fatigue

AS 3990 Steelwork for Engineering Applications

AS 4100 Steel Structures Code

AS 1511 High-strength Structural Bolting Code

AS1554.1 Structural Steel Welding – Part 1: Welding of steel structures

AS1554.4 Structural Steel Welding – Part 4: Welding of High Strength Quenched and

Tempered steels

AS1554.5 Structural Steel Welding – Part 5: Welding of steel structures subject to high

levels of fatigue loading

AS1065 Non destructive testing Ultrasonic testing of carbon and low alloy steel forgings

AS/NZS

1170.0

Structural design actions Part 0: General Principles

AS1171 Non destructive testing-Magnetic particle testing of ferromagnetic products,

components and structures

AS2574 Non destructive testing-Ultrasonic testing of ferritic steel castings

AS3507.2 Non destructive testing=Radiography determination of quality of ferrous casting

AS1654 Limits and Fits for Engineering

AS1657 Fixed platforms, walkways, stairways and ladders-design, construction, and

installation

AS1318 Colours-Safety Marking

AS1710 Non-Destructive testing of carbon and low alloy steel plate, test methods and

quality classification.

AS2012.2 Part 2: Acoustics - Measurement of airborne noise emitted by earth-moving

machinery and agricultural tractors

AS2080 Safety Glass for land vehicles



AS3637.1 Underground Mining - Winding Suspension Equipment Part 1: General

Requirements

AS3637.2 Underground Mining - Winding Suspension Equipment Part 2: Detaching Hooks

AS3637.3 Underground Mining - Winding Suspension Equipment Part 3: Rope Cappings

AS 3637.4 Underground Mining - Winding Suspension Equipment Part 4. Drawbars and

Connecting Links.

AS3637.5 Underground Mining - Winding Suspension Equipment Part 5: Rope Swivels and

Swivel Hooks

AS3637.6 Underground Mining - Winding Suspension Equipment. Part 6 Shackles and

Chains

AS3751 Underground Mining-Slope haulage-Couplings, drawbars and safety chains.

AS3785.1 Underground Mining-Shaft Equipment Part 1: Overwind safety catch systems

AS3785.2 Underground Mining-Shaft Equipment. Part 2: Shaft winding arrest systems

AS3785.3 Underground Mining-Shaft Equipment Part 3: Drum Winding Gripper Systems

AS3785.4 Underground Mining-Shaft Equipment Part 4: Conveyances for Vertical Shafts

AS3785.5 Underground Mining-Shaft Equipment Part 5: Headframes

AS3785.6 Underground Mining-Shaft Equipment Part 6: Guides and Rubbing Ropes for

Conveyances

AS3785.7 Underground Mining-Shaft Equipment Part 7: Sheaves

AS3785.8 Underground Mining-Shaft Equipment Part 8: Personnel Conveyances in other

than Vertical Shafts

AS3569 Steel Wire Ropes

AS4812 Non destructive examination and discard criteria for wire ropes in mine winding

systems.

AS4024.1 Safety of machinery (all sub-Parts as applicable)

AS4360 Risk Management

AS2671 Hydraulic fluid power-General requirements for systems (ISO 4413:1998, MOD)

AS2788 Pneumatic fluid power-General requirements for systems (ISO 4414:1998, MOD)

AS1085.1 Railway track material-Steel rails.

Department publications


Safe man riding in Mines parts 1A and 1B, parts 2A and 2B, being the first and

second report of the National Committee for Safety of man riding in shafts and

unwalkable Outlets.

MDG 26 Guideline for Examination, Testing and Retirement of Mine Winder Ropes for use

in coal mines

MDG 1010 Risk Management Handbook for Mining Industry

MDG 40 Guideline for Hazardous Energy Control (Isolation or Treatment)

EES008-1 Design of Power Winding Systems. Electrical Engineering Safety-General

Requirements and Registration.

EES008-2 Design of Power Winding Systems. Electrical Engineering Safety-Definitions and

Winder Types

EES008-3 Design of Power Winding Systems. Electrical Engineering Safety Requirements-A

Prescriptive Approach

EES008-4 Design of Power Winding Systems. Electrical Engineering Safety Requirements-

A Functional Safety Approach

EES008-5 Design of Power Winding Systems. Electrical Engineering Safety Requirements-

Life Cycle Management of Powered Winding Systems.

International Standards

ISO 4309 Cranes-Wire ropes-care, maintenance, installation, examination and discard.




APPENDIX B MINING LEGISLATIVE FRAMEWORK IN NSW

The following diagram outlines the Occupational Health and Safety legislative framework for coal mines in NSW.

APPENDIX C - DESIGN REGISTRATION MINE WINDERS

C1.1 Design registration

Insert relevant information from gazette to clause 107 OHS regs.

C1.2 Risk Assessment Report

Any application for equipment registration must be supported by a creditable Risk Assessment report. The risk assessment should be based on the document AS 4360 Risk Management and MDG 1010 Risk Management Handbook.

The Risk Assessment should be conducted to cover situations or areas where there are no codes or standards or where variations to codes or standards are required.

This document may be used as an aid in identifying hazards, however it should not be solely relied on for that purpose.

The application should contain a brief statement of compliance, variation, or reason for non-compliance with each item mentioned in this guide.

The application should contain results of tests and a statement of compliance with all requirements in accordance with Australian or other relevant standards, codes, or methods used.

The application should contain any further information, calculations, drawings or other documentation considered to be appropriate in supporting the application.

Full details covering electrical and control aspects to Part 6 will be required including as may be detailed by other guidelines, codes and standards.

Information as detailed in MDG 1010 shall be supplied.




APPENDIX D FEEDBACK SHEET

Your comment on this Guideline will be very helpful in reviewing and improving the document.

Please copy and complete the Feedback Sheet and return it to:

The Senior Inspector of Mechanical Engineering

Industry and Investment NSW

PO Box 344

Hunter Region Mail Centre NSW, 2310

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Thank you for completing and returning this Feedback Sheet.