DATE OF ISSUE:lS/6/92 CONTENTS Section 2 Winding Ropes
GU nz rOB THE cowsnucy:roworn CT ON w:rupgsNo MDG12-FILE REFERENCE: C82/3465DATE OF ISSUE:lS/6/92CONTENTSSection 1ScopeSection 2Winding RopesSection 3Winding Suspension EquipmentSection 4Shaft EquipmentSecti-{)n 5Winding MachinerySection 6Testing for CompliancePart APart BInspectionTestingAppendix IAppendix IIHead Rope Factor of SafetyExplanatory Notes
Guidefor the Cqnstrnctjon of Frjctiqn WindersPrefage:This Guidesetsout minimum requirementsf.or the design,installation and use of winding equipment installed. in shafts forthe conveyance of men and materials where the driving force istransmitted to the hoisting rope or ropes by friction between therope drum and rope.Manual, semi-automatic or automatic control may be adopted.The guide has been based on an orginal document entitled"Requirements for the use of Friction Winders" which was pr paredin 1971. This guide has been modified to incorporate theprovisions of the Coal Mines Regulation Act,1982 and itsRegulations together with the references to the current AustralianStandards · for shaft winding equipment and attachments. Testingrequirements have also been included which has been based on theexperience gained over a period of 20 years of the a ppr ovaltesting process.L.J.ROBERTSSENIOR INSPECTOR OF MECHANICAL ENGINEERINGPage 2 of 22
Guide for the Construction gf Frjctiqo Wjnders1.SCOPE1.1Clause 7 of the Coal Mines Regulation Act (Shafts andRoadwaysUnderground ulageapparatus used at a mine for transporting personsthrough any shaft or roadway be approved by the ChiefInspector.1.2Clause 9 (1) of· the Coal- Mines Regulation (Shafts andRoadwaysUndergroundMines)Regulation,1984,requ resthat conveyances used at a coal mine fortransporting persons through a shaft be of a typewhich· has been approved for the purpose by the ChiefInspector.1.3This guide is intended to assist manufacturers ofFriction Winders by indicating the design parameterswhich will be considered in theassessmentfor·.approval of equipment as referred to in 1 .1 and 1. 2.1.4The following definitions apply:"friction winder" means a shaft winding system inwhich conveyances are raised and lowered by means offriction between a head rope or head ropes and adriving sheave or sheaves;"conveyance" includes all types of equipment attachedto a friction winding systems in which persons aretransported;·-1.5Theguidedoesnotgenerally givequantitiveinformationasitis notintendedtorestrictinnovative design.Where specific values or ves to those included in this document,advice should be sought from Inspectors of MechanicalEngineering, Coal Mining Inspectorate and EngineeringBranch of the Department of Mineral Resources .I::I.Q.Il:L"shall" and "should"(a)"shall" means that the requirement is mandat oryif required under existing legisl ation or asdetermined by the Chief Inspector.(b)"should" means recommended.1.6Unless otherwise speci-fied, the appropriate AustralianStandards shall apply.1.7Where reference is made to a design standardcurrent published version shall be utilised.the·-·.Page 3 of 22
Guide for the Construction of Frjctiqn Winders'1.8This guide does not in any way negate the requirementsof the Coal Mines Regulation Act 67/1982 nor theOccupational Health and Safety AC , 1983, No 20.1.9Formall. 9.1Approval applicationsfollowing: and84,ingageonsief(A)and84,forypesnbrnjssjons fqr entreportwhicheffectively identifies, ·assesses and controlshazardsrelating to thesafety of personsassociated with the operation, maintenance andtesting of the complete Winding System.iefNote:of rs( 1) In general the risk assessment will coversituations or areas where there are no codesorstandardsorwherevariationsarerequired.:or· (2)inofa1ed1re(B)LvecctThis document may be used as an aid toassist in identification of hazards butshould. not solely be relied on for thatpurpose.Sourcesofotherrelevantinformation such as that contained withinthe First and Second Reports of the UKHealth and Safety Executive entitled "Safetyof Manriding in Mines" should be utilised asshould details of accidents or dangerousoccurrenceswhichhaveoccurredwithexisting winders.A brief statement of compliance, variation· orreasonfornoncompliancewitheachitemmentioned in this guide. stA marked up and signed copy of this ·guide may beused to indicate the status of the design.aslt,:al.ng(C)Results of tests and a statement of alian or other relevant standards.(D)Any further information requested within thisguide or as considered to be appropriate insupporting the application.(E)Full details pertaining to the type of controlfor winder operation i.e. manual, semi .!'automaticor automatic.· ··Jryas.an·1. 9.2: .:heDocumentation covering electrical . aspects. as requiredby the Department of Mineral Resources· ApplicantsGuide to obtaining an . approva-lfrom the .ChiefInspector of Coal Mines or an Accredited Assess2ngAuthority. 22Page 4 of 22
Guj de for the Cpnstructj on of Frj ct iop uirements of the -Coal Mines Regulation Act 67/],982,subsequentRegulations , andrelevantAustralianStandards.1.10Whilst primarily intended · for use with new frictionwinders, the guidelines where applicable will be usedas an integral part of the assessment process forapplications for approval of variations to existingapproved friction winders.2.wntp BG ROPES2.1GeneralAll ropes used in the construction of the frictionwinder system i.e. head, balance, guide and rubbingshall comply with the requirements of:(a)Coal Mines Regulation(Shafts and RoadwaysUnderground Mines) Regulation, 1984; and(b)The relevant sections of Australian StandardAS3569-1989 "Steel Wire Ropes" as applicable forwinder installations.2.2Rope Factors of Safety2.2.1Head Ropes.The factor of safety for head ropes shall be inaccordance with Appendix 1 - Notice of Specification :"Bead Ropes for Friction Winders."2.2.2Qther Ropes.The factor of safety for all other ropes such asbalance,guideandrubbingropesshallbeinaccordance with the Coal Mines Regulation (Shafts andRoadways - Underground Mines) Regulation, 1984.2.3Galvanised ropes should be used in shafts where the. quantity or chemical content of the moisture or waterwould cause serious corrosion to an ungalvanised rope.2.4The use of any form of rope dressing which may reducethe design coefficient of friction bet ween the headrope and the drive sheave is not permitted.2.5The winder should be designed for multiple head ropes.Page 5 of 22
'thel82,.ianGuide for the Constrpctj QD of Frier ion Winders3.WINQING SUSPENSION EQUIPMENT3.1MaterialThematerialusedinthe -manufactureofropeattachments and suspension equipment shall be inaccordancewith AustralianStandard AS3637 .1-1989"Underground Mining - Winding Suspension Equipment Part 1: General lsmaybeacceptableproviding that it can be demonstrated that they haveequivalent chemical and physical properties.ioning3.2ComponentsRope attachments -and suspension equipment shall be inaccordance with the relevant. sections of the followingParts· of Australian Standard. AS3637-1989 "UndergroundMining- Winding Suspension Equipment."Part 3:Rope Cappings.Part 4:Drawbars and Connecting Links.Part 5:Rope Swivels and Swivel Hooks.Part 6:Shackles and Chains. ·ardforNote: The use of detaching hooks is prohibited.4.SQFT EOUIPMINT4.1Headframes shall be in accordanceStandard AS3785.5-1991 "UndergroundEquipment- PartS: Headframes".4.2Conveyances shall be in accordance with AustralianStandard AS3785. 4.:1992 " Underground MiningShaftEquipment -Part 4: Conveyances for Vertical Shafts.":he:er4.3Each Friction Winder Conveyance shall be of a typewhich is compatible with the friction winding systemand has been alianStandard AS3785.7-1993 "Underground MiningShaftEquipment - Part 7: Sheaves" except as specified inClause 5.1.4.5Guides and rubbing ropes for conveyances shall be inaccOrdancewithAustralianStandard AS3785. 6-1992"Underground Mining - Shaft Equipment - Part 6: Guidesand Rubbing Ropes ·for Conveyances."in1:asinind:ad'.22with AustralianMiningShaftPage 6 of 22
Gujde for the Cqnstructjon qf Frjctjon Wjpders4.6Arresting systems to limit the effects of an overwincshall at least be in, accordance with AustraliarShaftStandard AS3785.2-1991 Underground MiningPart 2:· FrictionWinding Arrest insEquipmentSystems."Note: AS3785 Parts 1 and 3 fo:r Drum Winding OverwincSafety Catch Systems and Grippers do not apply tcfriction winder installations.4.7AccessIn addition to the provisions for access incorporatecinAS3585. 5 - "Headframes" the following access isrequired:4.7.1All platforms, walkways and ladders shall comply withAustralian Standard AS 1657-1985 Fixed Platforms,Walkways, Stairways and Ladders;4.7.2Provision shall be made at all working levels forpersonnel to safely embark and disembark from aconveyance;4.7.3Provision shall be made in the head frame and shaftsump by way of suitable pl-atforms and ladders, foraccess to an overwound cage and safe access forpersonnel leaving an overwound conveyance;4.7.4The space between the lowest stopping point and theshaft sump shall be equipped with ladders or othersuitable means of access to permit proper inspectionand maintenance of that part of the shaft. The accessfacilities shall be effectively enclosed;4.7.5Access landings acceptable to the authorities approvedto conduct non-destructive testing of head and balanceropes over their full length shall be provided.4.8A signal l.ine should be provided in the shaft fortransmission of data to the surface for recording ontesting equipment in the winder engine room.4.9The shaft sump shall be designed. so that the ingressof water, debris, or other material will be limited toan extent that will prevent the balance ropes orweights from contacting such water, debris, or othermaterial.4.10Any building or structure on the top of the shaftshall comply with the requirements of Clause 31 of theCoal Mines Regulation (Fire ControlUndergroundMines) Regulation, 1984.4.11Keps or chairing devices shall not be provided in theshaft except with the written approval of the . ChiefInspector.Page 7 of 22
There shall be provided in the shaft, headframe, ortower such devices as will remove the power from thewinder and, by automatic application of the ance,cage,skip,counterweight,orropeattachment reaches any permanent obstruction to itspassage. Such devices shall be in addition to theautomatic contrivance requ"ired by Clause 5.6. indLian1aft:ing-rindto5.'5.11tedis5.1 ( i)rith:ms,Rope SizeSheayea/Rppe CgpfiqurgtignThe ratio of winding sheave to rope diameter shall notbe less than the following: StrandedNo er.afttheundtheief22BendingNo ReverseBendingBendingUp to31. 75mm dia. 70:180:185:195:1From 31. 75mmto 44.45mm dia80:190:195:1105:1Above 44.45mmdia.85:195:1100:1110:15.1(ii)The coefficient of friction between the rope treads onthe driving sheave and the winding ropes shall be suchthat there will be no slip under normal Suchcoefficient shall not be less than 0.2 .5.1(iii)The grooves in a multi-groovedsame sheave diameter.5.1 (iv)T ediameter of any deflecting sheaves shall be notless than 0. 9 times the diameter of the correspondingdriving sheave.5.1 (v)The angle of .contact of the rope on deflecting sheavesshall be sufficient to prevent the rope slipping onthe sheaves.5.2Unless otherwiseInspector:5.2(i)In raising or lowering material t.he maximum windingspeed shall not exceed 20 metres per second.5.2 (ii)In raising or lowering persons the maximumspeed shall not exceed 15 metres per· second. ved.neeforonLocked Coilapproved -insheavewritingshallbybethetheChiefwindingPage 8 of 22
.- Gnj de for the Constrn t iop of Frj ct ign Wj nders5.2(iii)In raising or lowering persons the maximum approachspeed to the shaft top and bottom shall not exceed 3. 5metres per second.5.3Every . friction winding engine shall be provided withtwo or more mechanical brake systems each of which:5.3 (i)Howsoeversheave.;.5.3(ii)Shall be designed, adjusted and maintained to safelystop and hold the conveyance, cage or skip under allconditions of loading, direction of travel and speed;5.3(iii)Will be capable of producing a braking torque of notless than two and a half times the maximum statictorque which will. be applied to the winding sheave bythe normal load;5.3(iv)Is·. sufficienttocauseretardationunderworstconditions of rtot less than 1 m/sec2 when windingpersonnel and 0.5 m/sec2 when winding material;5. 3 (v)Will result in a retardation rate of not more than 3.5m/sec2 when winding personnel;5.3 (vi)When applied by any means other than those set out insub-paragraph (ii) above will produce a braking torqueless than will cause the winding rope to slip undulyon the winding sheave;5.3 (vii)Howsoever applied will not produce a braking torquewhich will cause a dangerous rate of retardation;5. 3 (viii)Can be applied irrespective of the action of anysafety device that may act to apply the brake, orbrakes;5.3(ix)Will be automatically applied when the supply of powerto the.winder fails;5.3(x)Will be automatically applied when the pressure of anyfluid or other. medium used as a means of controllingthe brake falls below the value necessary to producethe braking torque required by sub-paragraph (iii) ofthis condition;5.3(xi)Shall be provided with a steel tension member betweenindividual soleplates of·· brake shoes;5.3(xii)Will be automatically applied if ah earth fault occursin the control circuit;5.3 (xiii)Will be automatically applied if the relative speedbetween the ropes and the sheave periphery differs by1.5 metres per second or more;appliedshallactdirectlyon thedrivingPage 9 of 22
. Guide fqr the Construction of Frictjqo Winders;h.55.3 (xiv)The brake system components shall be designed againstfatigue failure;5.3Where a system of electrical braking is included, itsuse shall not be prevented by any emergency stop; and(XV):hLyLl5.3 (xvi)The winder shall be provided with a device toautomatically apply the brake before the brake becomesworn sufficiently to effect its safe operation.5.4Every winderdesigned andoperated theexcept thatremoved from5.5Every winder shall be provided with depth and speedindicators driven from a sheave shaft and so placed asto be. readily seen.5.6Every winder shall be provided with an effectiveautomatic contrivance to prevent over-winding andover-speeding so constructed as: 5. 6 ( i)To prevent the descending conveyance or skip fromexceeding a speed 15% greater · than the maximumdesigned speed and to ensure progressive reduction ofspeed during retardation to prevent overwinding atexcessive speed, under any condition of loading;5.6(ii)To control the movement of the ascending cage or skipto prevent danger to any person therein; and5.6(iii)To stop the winder when the conveyancepersonnel travels beyond the brace.5.7Every winder shall be provided with a device whichwill automatically synchronise the depth indicator andthe automatic contrivance required by ·Clause 5.6 withthe position of the cage or skip in the shaft. Suchsynchronising adjustment shall take place only whilethe brakes are applied and the winder is not winding.5.8When a winder is being used for the carriage ofpersons and its operation is under push button controlfrom within the cage it shall be incapable of motionunless all, shaft doors and cage or skip doors· inconnection with that winder are properly closed. Alllimit switches 1,1sed for·. this purpose shall be seriesduplicated.··5.9Any device provided to permit backing out of anoverwind position shall respond to mariual .c ontrol onlyand sh,3.ll not permit· backirig .out in a wrong direction.Jtshall be provided with a stop switch soconstructed as to ensure that when it isbrakes will be applied, and all power,required for electrical braking will bethe winder.LcJY3t.5LnleLy1ycarryingJr n:s22Page 10 of 22
Guide for the Constructjon gf Frjctjon Winders5.10Where lt is arranged that the winder may be controlledby more than one method. (manual, push-button and/orother) the device for selecting any control methodshall be available only to authorised persons.5.11Push-button controls located at any landing shall onlybe accessible to a person inside a conveyance when theconveyance door is open.5.12Push-button controls shall be effective from one pointonly until that operation is completed. All automaticcontrols shall fail to safety.5.13Where it is arranged for push-button control of thewinder from within a conveyance, a stop button shallbe provided which, when operated, will cause thewinder to stop.5.14In every case where the winder is situated in the·headframe or tower of a shaft effective precautionsshall be taken to prevent any flammable liquid used inconnection with the winder or any apparatus installedin the headframe or tower from entering the shaft.5.15In every such case where the winder is not undersuperv'ision an automatic fire suppression system withthe capacity of extinguishing any fire which may breakout in the winder room and with a suitable alarmsystem shall be provided.5.16Provision to be made in the winder control circuitrecording apparatus, to monitor the winding tion rates and position of the conveyancecage(s) or skip(s) in the shaft.forandand(s),These provisions will be required for commissioningtests and regular inservice testing throughout thelife of the installation.5.17Production winding installations to be provided withinterlocks to indicate and . control the winding cycleto pre-set parameters when the winding equipment . isbeing ·used. to transport personnel .Page 11 of 22
TJiST NG I'OB -CQMPL ltNCiiedorodPart A -y.eThe following matters are required to be included inthe manufacturer's program for inspection prior tocommencing operational commissioning tests .r:,:··:rnapeqtign6.1D sjgn6.1.1Statements to be supplied by equipment manufacturerssetting out the design standard adopted for structuralcomponents of headframe, shaft landings, machinery andtower foundations etc.he6.1.2Brake systems designed againstfactor concept.hensined6.2Details of Eq.uipment6.2.1Shafts:nticJ .:;. . hethleis(j)(k)6.2.2Overtravel limits; to be duplicated.Mechanical brake dump valve.Arrestors for conveyances and counterweightspecifications required.Drop back catches - design details required.Keps, chairing devices or grippers - not allowedexcept with approval of Chief Inspector of CoalMines. Conveyance, cage or counterweight detaching - notallowed.Provision for drainage of sump.Provision of access to landings and enclosures:Provision of access :).andings for non-destructiverope testing.No flammable fluids to enter shaft from towerwinding engine room.Automatic fire extinguishing equipment in tower.Machinery:(a)(b)(c)(d)(e)(f)22fatigue using reserveDeflecting sheaves not less than 0. 9 times ropedrum diameter.Rope drum tread diamet er to rope diameter ratio:should be between 70 to 1 and 110 to .1 dependingon rope type and size.Coefficient of friction between the rope and ropedrum not less than 0.2.Rope grooves on multi--rope drums to be dspecification.·Drawing details for engine· compone .ts and controlcomponents to be checked.Page 12 of 22
Guide for the Constructjgn of Frjctjon Winders6.2.3Mechanical Brakes:(a)(b)(c)(d)(e)(f)(g)6. 2. 4Control Systems:(a)(b)(c)(d)(e)(f)6.2.5Two or more brake assemblies to be provided ancapplied directly to the winding drum.Steel tension members between the
Standard AS3785. 4.:1992 " Underground Mining Shaft . 4.7.1 All platforms, walkways and ladders shall comply with Australian Standard AS 1657-1985 Fixed Platforms, Walkways, Stairways and Ladders; 4.7.2
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