HOIST & HAUL 2015 Proceedings of the International Conference on Hoisting and Haulage Edited by Borje Johansson HOIST & HAUL 2015 Proceedings of the International Conference on Hoisting and Haulage Held in Stockholm, Sweden Edited by Borje Johansson PUBLISHED BY THE SOCIETY FOR MINING, METALLURGY & EXPLORATION Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. !SME_HoistHaul2015_TitlePg_L3.indd 1 4/15/15 4:13 PM Society for Mining, Metallurgy & Exploration Inc. (SME) 12999 East Adam Aircraft Circle Englewood, Colorado 80112 (303) 948-4200 / (800) 763-3132 www.smenet.org SME advances the worldwide mining and minerals community through information exchange and professional development. SME is the world’s largest association of mining and minerals professionals. Copyright © 2015 Society for Mining, Metallurgy & Exploration Inc. All Rights Reserved. Printed in the United States of America. 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No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. ISBN: 978-0-87335-418-9 On the Cover Title: Kiruna View Source: LKAB, used with permission Photographer: Fredric Alm Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. Contents Preface ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․vii Brakes and Brake Controls Safety Brake Systems for Mine Hoists—Applying SIL to the Mine Hoist Brake System ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 1 Tim Gartner Hoist Brakes—Disc or Caliper Shoes: How Do They Compare? ․․․․․․․․․․․․․․․․․․ 11 Roy M. Harwood, Michael Yates Design, Operation, and Maintenance of Ropes Securing Safety of Ropes with a Visual Rope Inspection System ․․․․․․․․․․․․․․․․․․ 25 Richard Söhnchen, Sven Winter, Konstantin Kühner Investigation of Synthetic Ropes for Use in Friction Hoists ․․․․․․․․․․․․․․․․․․․․․․ 33 Gregory Simmons Control of Catenary Rope Oscillation on a Blair Multi-Rope Winder by Unbalancing the Load Sharing Between the Hoist Ropes ․․․․․․․․․․․․․․․․․․․․․․․ 43 Bob Townsend Axial and Rotational Slippage Behaviour of a Hoisting Rope Passing Over a Friction Drum ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 53 Rodney Hamilton Stress Analysis and Lifetime Extension of Hoist Rope ․․․․․․․․․․․․․․․․․․․․․․․․․․ 73 Yujin Li, Baolian Zhang, Yong Yu Changing Koepe Friction Hoist Tail Ropes from Surface Without an Underground Tail Rope Changing Level ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 83 Derek Naude High-Performance Synthetic Ropes for Mine Hoisting ․․․․․․․․․․․․․․․․․․․․․․․․․ 99 Allan J. Guse, Mark Huntley Cost-Benefit of Replacing Wire Ropes by Equivalent High-Performance Aramid Synthetic Ropes for Production Mine Hoisting in a Deep Mining Operation ․․․․․․․ 111 R.J. Gaëtan, Otto Grabandt, Allan J. Guse A New Method for Automatic Reduction of Catenary Oscillations in Drum Hoist Installations ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 125 Borje Johansson, Apasara Steinarson Motor, Drives, and Supply Advantages of PWM-Fed Induction Machine Applied to Mine Hoists ․․․․․․․․․․․․ 141 Paul H. Noy Interaction Between Harmonics from a Large Mine Hoist Drive and the Changing iii Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. iv CONTENTS Power Network of a Mine Under Construction: Real Case and Solutions ․․․․․․․․․․ 151 Paul Henri Losses and Efficiency in Hoisting Systems ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 163 Peder Johansson Mine Hoist Drive Applications Powered from Diesel Generators ․․․․․․․․․․․․․․․․ 183 Harold Harkonen, Matt Raison AC Drive Selection for Mine Hoists ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 191 Andrew Theal Stewart Key Technology Research on Explosion-Proof Converters Based on Back-to-Back Double Three-Level Topology ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 203 Guo-Jun Tan Ingedrive MV100: A Medium Voltage and Full Power Redundant AC Drive for Driving the Tongting Mine Hoist System ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 221 Iñigo Atutxa, Arkaitz Gaztelu, Iñigo Torre, Juan José Valera Hoist Control Based on Safety Integrity Level (SIL) or Performance Level (PL) Standards An Illustrated Journey Through Functional Safety—Lessons from History ․․․․․․․․ 233 Michael R. Taylor Functional Safety for Mine Hoist—From Lilly to SIL3 Hoist Protector® ․․․․․․․․․․․ 245 Anders Taqvist The Implication of Choosing a Certain Functional Safety Standard for Hoist and Haul Applications ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 265 Johan Hedberg, Andreas Söderberg Functional Safety Standards and Application to Upgrading Mine Hoists ․․․․․․․․․․ 273 Daniel J. Lovisa Hoisting System Elements Developments in Computerized Systems for Mine Hoist Control ․․․․․․․․․․․․․․․․ 281 David A. Stefou Emergency Braking of Mine Shaft Hoists Applying Friction Arresting Devices— Theory, Tests, and Industrial Applications ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 291 Tomasz Rokita, Marian Wójcik Lightweight Skips—Factors Influencing Operational Reliability ․․․․․․․․․․․․․․․․․ 301 S. Gorzalczynski Underground Horizontal Transport KUJ 1365—A New Main Haulage Level in the LKAB Kiruna Mine ․․․․․․․․․․․․․․․ 313 Hans Engberg Sliding Mode Control for Path Tracking of Underground Mining Articulated Dump Truck ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 323 Jue Yang, Xuan Zhao, Yaodong Yang Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. CONTENTS v Incline Transport: Hoist, Conveyor, and Truck Thermal Analysis of Cooling Network System for Driving Motor of Underground Articulated Dump Truck ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 333 Yanhua Shen, Wenming Zhang, Guixia Liu Benefits of High-Powered Gearless Conveyor Drives Applied to Medium-Power Conveyors ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 345 Ulf Richter The Power of Steel in Hard Rock Haulage by Hoist and Belt Conveyor ․․․․․․․․․․․․ 353 J.C. Spreadborough Comparison of a Hoisting System and Vertical Conveyor for Shallow Shafts ․․․․․․․ 367 Eric Boutin, Steve K. Nix Shaft Guiding Systems Investigation on Conveyance Motion Using CFD and Structural Analysis ․․․․․․․․․ 375 Quan Situ, Thomas Li, Julius Butty The Use of Rope Guides for Deep Shafts ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 389 Malcolm Greenway Depth Limitations for Rope-Guided Conveyances ․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 415 Stuart Wilson Shaft Systems: New and Upgrade Incorporation of Multiple Best Practices in Very Large Friction Hoist Systems ․․․․․ 427 Jason Morrow, Dave Richardson Design and Construction of Tall Structural Steel A-Frames for Ground-Mounted Mine Hoists ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 439 Brian M. Mashford, Timo K. Tikka Concrete Headframe Supported on a “Bridge” ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 449 D.M. Ziebarth, R.M. Heppler Conversion of a Service Shaft to a Production Shaft ․․․․․․․․․․․․․․․․․․․․․․․․․․ 459 D.M. Ziebarth, R.M. Heppler New Hoisting Systems for Garpenberg Mine, Boliden, Sweden ․․․․․․․․․․․․․․․․․․ 471 Fredrik Ögren High-Capacity Hoisting Systems in Canadian Potash with PCS Allan Focus ․․․․․․․ 487 M.K. Tomtene, T. Gartner Ernest Henry Mine Shaft Hoisting System—Case Study ․․․․․․․․․․․․․․․․․․․․․․․ 499 Angelo Leonforte George Fisher L72 Shaft Hoist—Case Study ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 517 Colin Rossetti, Anthony Green Addressing Challenges of Concrete Strength Development of Mine Shaft Liner Cured Under Frost Exposure ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 535 Amir Golpaygan, Jimmy Susetyo Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. vi CONTENTS 37-Ton Drum Shaft and 18-Ton Drum Quarters—Using Newest 3D Scanning Technology for the Preparation and Slinging Procedure Down a 1700-m Vertical Shaft ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 545 Lenerd Louw High-Speed Load-Out Conveyor Designs and Skip Loading Time Optimization ․․․․ 561 Michael J. Peden Design Loads on Boxfronts ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 579 Geoffrey J. Krige Progress Toward International Standards for Mining Structures ․․․․․․․․․․․․․․․․․ 595 Geoffrey J. Krige Case Study: Cost Optimization with the Use of a Hooke’s Joint on a Blair Multi Rope Hoist (Mopani Deeps Project) ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 605 Francois Koekemoer, Dzianis Yahorau Design and Selection of Hoisting Plants in the 21st Century—The Inevitability of Change ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 623 Chris Dougherty Design and Operational Considerations in the Development of Internal Shafts or Winzes ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 633 Chris Dougherty Hidden Costs of Used Hoists ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 649 Ian Armitage Steel for the 21st Century Mining Industry ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 663 C. Mawdsley Upgrading, Modernising, and Refurbishing Existing or Secondhand Mine Winders for Continued and Future Use ․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․․ 675 G.L. du Plessis Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. Preface The Society for Mining, Metallurgy and Exploration (SME) offers a warm welcome to all attendees of the 2015 International Conference on Hoisting and Haulage in Stockholm, Sweden. Hoist and Haul 2015 is the 8th international conference on the theme that started in Johannesburg, South Africa, in 1973; followed by Toronto, Canada (1988); London, England (1992); Krakow, Poland (1998); Johannesburg, South Africa (2000); Perth, Australia (2005); and Las Vegas, Nevada (USA) in 2010. The conferences have been well attended, representing a wide field of expertise including academia, government representatives, mine operators, consultants, and manufacturers. The papers presented offer unique opportunities for delegates to stay current on the latest technologies, statutory requirements, and best practices, and to connect with other professionals in the industry. Mining continues to be driven by economies of scale. Ore bodies are explored at greater depths. This requires larger payloads to be transported at higher speeds, which need larger and more powerful equipment than currently available. This proceedings volume covers a wide range of topics including hoisting, convey- ing, and rail and truck haulage. Papers from 10 countries encompass complete transport systems, subsystems and components, design, installation, maintenance, and econom- ical aspects. Innovative technologies and new methods are also introduced. All papers in the proceedings have been peer reviewed to ensure the highest relevance and quality. Important developments in mine hoisting are the new requirements on safety that have already been implemented in some regions and in an increasing number of con- tracts. There are currently two standards for the new requirements on safety: one defining Safety Integrity Levels, or SILs, 0 to 4, and the other, Performance Levels, or PLs, a to e). Both define the probability of hazardous faults and events. The applicable standards can be interpreted in different ways when applied to mine hoists. This conference is an excellent opportunity to discuss how the standards are interpreted with the objective of reaching a common understanding and approach when defining new safety require- ments for mine hoists. SME and the organizing committee thank all authors, peer reviewers, and their companies for their valuable contributions. Thanks are also extended to the mines who have organized the postconference visits. vii Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved. Editor Borje Johansson Organizing Committee Wenqing Cui Oswald Deuchar Borje Johansson Jose Moschioni Daniel Nolkrantz Peer Reviewers Patrick Bateman Daniel Lovisa Ronnie Bawden Dick McIvor Peter Brokenshire Graeme Medhurst Chris Dougherty Derek Naude Graham du Plessis Bob Provonost Julian Fisher Colin Rossetti Malcolm E. Greenway Peter Saxby Steve Grobler Anders Taqvist Al Guse Socrates Vakilis Rodney Hamilton Stefan van der Watt Roy Harwood Richard Vergottini Johan Hedberg Peter Warner Stephen Keen Mathew Watt Geoffrey J. Krige Stuart Wilson Angelo Leonforte Dwayne M. Ziebarth ix Copyright © 2015 Society for Mining, Metallurgy, and Exploration Inc. All rights reserved.