MDG 33.4 part 4 shaft sinking winders - NSW Resources and ... · PDF fileTrade & Investment...

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011

GUIDELINES

MINE WINDERS

PART 4: SHAFT SINKING WINDERS

MDG 33.4

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 4_Shaft sinking_Industry DRAFT 111028.doc

MDG 33.4 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 33.4 Page ii

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

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.4 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 4.

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 MDG 33.1. Constructive comment is essential to help the Department improve this Guideline.

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.4 Page iv

CONTENTS

Foreword................................................................................................................................. iii

1 PURPOSE AND SCOPE ....................................................................................................... 1

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

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

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

1.4 abbreviations and definitions ............................................................................................................... 1

2 Shaft Sinking ........................................................................................................................ 2

2.1 General Requirements for Shaft Sinking ............................................................................................. 2

2.2 Shaft Sinking Winders.......................................................................................................................... 6

2.3 Shaft Doors .......................................................................................................................................... 6

2.4 Interlocking........................................................................................................................................... 7

2.5 Winder Movement................................................................................................................................ 8

2.6 Shaft Top Doors................................................................................................................................... 8

2.7 Guide Systems..................................................................................................................................... 8

2.8 Kibbles and Equipment ........................................................................................................................ 8

2.9 Arrestor Equipment ............................................................................................................................ 10

2.10 Brakes .............................................................................................................................................. 10

2.11 Ropes............................................................................................................................................... 10

2.12 Rope and Conveyance Attachments ............................................................................................... 10

2.13 Stage Winders.................................................................................................................................. 11

2.14 Stage Winders and Stage Equipment.............................................................................................. 12

APPENDIX A Feedback Sheet.............................................................................................. 14

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 shaft sinking winders

1.2 SCOPE

This guideline sets out recommended minimum safety requirements for the design, construction and maintenance of shaft sinking winders.

1.3 APPLICATION

This Guideline applies to all mine shaft sinking winders.

This guideline should be used by designers, manufacturers, owners and users when – (1) Designing new mine shaft sinking winders

(2) Independently verifying mine shaft sinking winders

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

(4) Altering existing mine shaft sinking winder winders

(5) Carrying out five yearly audits on mine winders

(6) Reviewing winder designs following an incident

(7) Altering, maintaining or repairing mine shaft sinking winders

1.4 ABBREVIATIONS AND DEFINITIONS

For the purposes of this Guideline, the abbreviations and definitions in MDG 33.1 apply.

1.5 STANDARDS AND GUIDELINES

The Australian Standards listed in Error! Reference source not found.are applicable to friction winders:

Trade & Investment – Mine Safety Issued Industry DRAFT November 2011 MDG 33.4 Page 1

MDG 33.4 Mine Winders – Shaft sinking winders

2 SHAFT SINKING

2.1 GENERAL REQUIREMENTS FOR SHAFT SINKING

Vertical shaft sinking is specialised work and should be undertaken by an experienced shaft sinking contractor. Because they do not have a shaft to start with, shaft sinking winders and their associated stage winders have requirements that are different to those of permanent winders. The methods used for shaft sinking vary, also, and often demand considerable flexibility. However, as with permanent winders, safety shall not be compromised. All the safety features required for powered winding systems shall be satisfied.

This Guideline is not intended to cover every type of shaft sinking operation, however, it may be used as a guide to an acceptable method, i.e. with kibble and stage winders. Other methods may meet the guideline’s intentions.

The shaft sinking project will normally use a vertical shaft drum winder with a kibble as the means of personnel and materials transport, and a movable stage consisting of several working platforms lowered and raised by another shaft drum winder, low speed, stage winder.

Because of the nature of the shaft sinking operation, and the difficulties encountered, some safety features normally required for permanent winders may be, with written approval, exempt.

In general the winders used for the shaft sinking operation shall conform to (Part 3, Section 5: Vertical Shaft Winders, Design and Construction), and other parts referred to under that section, as required.

Subject to written approval, and to conditions applying to the activity, the contractor may use a crane, with a kibble or bucket attached, to hoist the broken rock from the initial surface excavation, and from the shaft, to a maximum depth of 50 metres. A crane shall not be used where the shaft perimeter has been traversed by beams or any other structure which could obstruct the free passage of the kibble or bucket.



Shaft Sinking Winder Cage

Modern Shaft Sinking Winder in position over a shaft


2.2 SHAFT SINKING WINDERS

2.2.1 General

Shaft sinking winders are those that wind personnel and/or materials in a vertical conveyance either a cage when winding only personnel or a kibble (or bucket) when winding both materials and personnel in the shaft, using a single rope coiling onto a drum. The winder drum and driving machinery can be located in a house or room at ground level, at a distance sufficient to give the required fleet angle, with the rope being positioned over the shaft by a head sheave and supporting headframe structure. Or as pictured on the previous page, a complete self contained unit mounted on foundations adjacent to the shaft.

2.2.2 Overwind Protection

For shaft sinking purposes approval may be granted to eliminate a detaching hook. Where detaching hooks are not used, the headframe shall include, for each conveyance, a penultimate overwind switch and an ultimate overwind switch, connected into two different control circuits each of which is arranged to cut off the power to the winder and apply the mechanical brakes. These switches shall be connected to tensioned trip wires or similar devices operated by the conveyance.

The overwind distance above the ultimate overwind switch should be sufficient to allow the conveyance to be brought safely to rest with 50% of the mechanical braking effort from the maximum monitored approach speed (not greater than 2 m/s).

A crash beam designed to resist rope break strength plus 20% shall be located under the head sheave. For this purpose the sheave support beams may be used.

The movement of the conveyance shall be controlled to minimise the risk of collision with the stage. The automatic contrivance should be regularly adjusted to ensure that the speed of the conveyance cannot exceed 2 m/s when it is at or below the top level of the stage.

2.3 SHAFT DOORS

During shaft sinking operations adequate provision shall be made, and maintained, to prevent spillage falling down the shaft during dumping operations.

A door, or doors, for covering the sinking compartment shall be provided, and maintained, at the collar of every shaft while sinking operations are in progress.

The shaft door, or doors, shall be kept closed at all times when personnel, tools or materials are being loaded onto or unloaded from the kibble or cage at the collar of the shaft, or when the kibble is being dumped, unless suitable alternative protection is provided to prevent spillage falling down the shaft.

Any doors or other shaft protective devices which, when moved into the haulage way or travel area of a shaft would interfere with the free passage of the conveyance, shall be so equipped that their position is positively indicated to the winder driver.



Shaft Top Doors in closed position

Shaft Top Doors in open position

2.4 INTERLOCKING

Interlocking with the kibble winder control system shall be provided so that:

When winding is taking place, tipping chutes are clear of the path of the conveyance.


During an ascending wind, the shaft top doors are open whenever a conveyance is in a zone extending from a safe stopping distance below the doors until it is above the doors.

Before discharging conveyances into the tipping chutes, all shaft top doors are closed.

2.5 WINDER MOVEMENT

Where there are two winding systems in the same shaft they shall be interlocked so that whenever either system is selected for personnel winding, the other cannot be used in any alternative mode.

2.6 SHAFT TOP DOORS

Persons shall not be allowed to enter or leave a conveyance, or to load materials into or unload from a conveyance at the collar level, unless the doors have been closed and the conveyance lowered onto them.

2.7 GUIDE SYSTEMS

2.7.1 general

There shall be provided in every sinking shaft exceeding 50 metres in depth, guides and guide attachments to prevent the kibble or conveyance from swinging while being lowered or raised in the shaft. Because the bottom of the shaft is moving downwards as shaft depth increases, guide systems used in permanent vertical shaft drum winders are not applicable to shaft sinking.

2.7.2 Guide ropes

In general the stage winder ropes are used as the guide ropes for the cage or kibble. For kibbles a crosshead (or monkey), is mounted on the main winder rope above the rope attachments to prevent the conveyance from swinging while being raised or lowered in the shaft. The crosshead slides on the stage winder ropes on brass slippers. For cages, guides with brass slipper inserts are located on each side of the cage.

For rope guides, the ratio of crosshead depth to width should be approximately 1.5:1 unless proven designs are used.

2.7.3 crosshead

The crosshead shall be installed whenever the shaft depth exceeds 50 metres and maintained to a distance of not more than 25 metres from the bottom of the shaft until the shaft sinking has been completed.

2.8 KIBBLES AND EQUIPMENT

2.8.1 general

The kibble (or bucket) used for shaft sinking shall be sized to suit the shaft, winder, and load capacity required, and shall be of such a shape as to minimise the risk of it catching on any obstruction during its travel in the shaft. Generally, the kibble is an open type bucket with two (2) or three (3) point attachment lugs equally spaced around the perimeter for attaching the lifting chains. A “lazy sling” arrangement is sometimes used to tip sinking kibbles.

2.8.2 Kibble Design and Construction

The kibble design is relatively simple compared to a skip or cage. However the structural factors of safety given for personnel riding conveyances shall be observed where the kibble is used for carrying personnel.

For structural strength requirements see AS3785.4-2002 Underground mining-Shaft equipment Part 4: Conveyances for vertical Shafts.

Kibbles designed to be self tipping on the release of a locking mechanism shall not be used for personnel riding.


Any kibble used for personnel riding shall be sufficiently sized as to prevent persons falling out. An individual travelling in a kibble where more than one third of his/her body is outside the conveyance, shall use a safety belt securely anchored inside the kibble.

Any kibble used for personnel riding shall have falling object protection fitted.

Any kibble used for personnel riding shall have sufficient toe holds, steps and hand holds, to allow safe loading and unloading of persons.

Chains used for suspending kibbles shall be of identical dimensions and strength, except where two-legged chains, consisting of a standard and a long chain, are used.

Chains used for suspending kibbles shall be of sufficient length to ensure that the included angle at the apex of the suspension of any two chains is not greater than 60 degrees.

Chains used for suspending kibbles shall comply with AS3637.1-2005 Underground mining-Winding suspension equipment. Part 1: General requirements and AS3637.6-2005 Underground mining-Winding suspension equipment. Part 6: Shackles and chains.



Any stairways, platforms or ladders used for safely loading or unloading persons to or from a kibble being used shaft sinking operations shall conform to AS 1657-1992 Fixed platforms, walkways, stairs and ladders-Design, construction and installation..

2.9 ARRESTOR EQUIPMENT

Arrestors are not required when shaft sinking, due to the problems that would be associated with conveyance arrestors at shaft bottom.

2.10 BRAKES

The guidelines set out in Part 3. Section 5: Vertical Shaft Winders Design and Construction. 5.12 Brakes, as requirements for drum winder brakes are also applicable for shaft sinking winders.

The cage/kibble brakes shall be statically tested to 200% of maximum static torque applied by the load at the drum at the commencement of each working day.

2.11 ROPES

The guidelines set out in Part 3. Section 5: Vertical Shaft Winders Design and Construction. 5.9 Vertical Shaft, Drum Winder Ropes, as requirements for drum winder ropes may not necessarily apply to all shaft sinking winders.

For design purposes select rope construction, diameters and strengths as set out in AS3569-1989 Steel wire ropes, consideration should also be given to AS1418.1-2002 Cranes, hoists and winches. Make the final selection and recommendation in co-operation with the wire rope manufacturer.

Before the winder commences each new project a Non Destructive Test and a Destructive Test shall be carried out on the ropes.

2.12 ROPE AND CONVEYANCE ATTACHMENTS

The guidelines set out in Part 3. Section 5: Vertical Shaft Winders Design and Construction. 5.4 Safety Devices for Vertical Shaft Drum Winders and 5.10 Rope Attachments as requirements for vertical shaft winders are also applicable for shaft sinking winders.

When selecting the attachments to be used, expert guidance should be sought from a reputable manufacturer. The use of AS3637-1 to 6"Underground Mining - Winding Suspension Equipment" should be used as a reference.


2.13 STAGE WINDERS

2.13.1 general

Stage winders are used during shaft sinking for lowering, raising and adjusting the stage in the shaft. As fare a reasonable practicalbe the stage winder requirements shall be as those for vertical shaft drum winders (see Section 5). However, due to the nature of shaft sinking operations some deviation from winding practice may be unavoidable.

2.13.2 Stage Winder Brakes

The guidelines set out in Part 3. Section 5: Vertical Shaft Winders Design and Construction. 5.12 Brakes as requirements for drum winder brakes are also applicable for stage winding, with the following specific features.

Band brakes shall not be used.

Brakes for stage winders may be exempt from dynamic testing.

The brake capacity required for each brake of every stage winder shall be 200% of the maximum static torque with the stage at shaft bottom.



Stage winder brakes winders shall be statically tested before being used in any new shaft sinking application after the winder has been installed on site and before the shaft sinking commences and subsequently tested before each movement of the stage takes place.

Brake application timing may permit the high speed (short reaction time) brake to engage first in order to assist stage levelling adjustments.

2.14 STAGE WINDERS AND STAGE EQUIPMENT

The shaft sinking stage is a moveable single or multi-deck structure suspended in the shaft and designed to form a working platform for shaft sinking activities.

The stage structure design loads shall be in accordance with AS3785 Part 4–2002 Conveyances for Vertical Shafts. A stage is defined as a conveyance.

Stages shall be securely fenced to prevent persons from falling. Stairways, platforms and ladders shall comply with AS1657-1992 Fixed platforms, walkways, stairways, and ladders-Design, construction and installation.

Stages shall be designed to minimise the possibility of overturning.

Ropes shall be attached to the stage through apparatus designed to load the ropes as uniformly as is practical.



Any part of the stage structure which is constructed using hinged sections shall be securely bolted together before persons are allowed to work on the structure during shaft sinking activities.

While the stage is stationary in the shaft it shall be secured to the side of the shaft by jacks or other devices to prevent it swinging.

Top deck of stage in shaft below surface collar



APPENDIX A STANDARDS

DRAFTING NOTE: Create list of referenced standards

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