Case Study: Improve shaft inspection knowledge among shaft inspection personnel and shaft supervisors

Requirements: Our customer required a customized course to train a variety of new and experienced shaft inspectors on two different types of shafts they regularly have to inspect and maintain at the site.

The customer had a high turn over in their shaft maintenance personnel which resulted in a loss of valuable shaft inspection information. This information is typically acquired through many years of experience.

The shaft inspection training had three main objectives:

1. To provide an evaluation of the skills of the personnel assigned to the inspection of the shaft(s)
2. To provide an evaluation of the condition of the shaft and maintenance practices
3. To provide information and training to be used by the inspectors to upgrade their inspection skills

This course included classroom instruction combined with hands on evaluations during a “typical” shaft inspection through one of the mine’s shaft compartments.

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Case Study: Improve hoist plant knowledge among maintenance personnel

Requirements: Our customer required a customized maintenance training package for their hoist plant. Other courses available were not specific to their hoist plant.

A training course was developed to cover the specific hoisting plants on the customers site. The training included hoist and brake control, lubrication, brake maintenance, electrical and mechanical maintenance and other components of the hoisting plant.

The courses were also designed to point out and cover the specific local regulatory requirements.

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Case Study: Customized log book training

Requirements: Provide customized log book training for operators, maintenance personnel and supervisory staff.

The Ministry of Labour equivalent for most jurisdictions requires that a set of log books is maintained for the hoisting plant by the Hoist Operators, Electricians, Mechanics and Shaft Inspectors.  The details of all inspections, testing and maintenance work are to be recorded in these books by the disciplines completing the work.  These books essentially become legal documents through the life of the mine.

The objective of this course is to provide a detailed approach on how to complete and manage the entries so that the information is consistent, clear, concise and focused to meet the requirements of the ministry and to also provide a good history on the maintenance of the equipment in the hoisting plant.

This course can be designed to be delivered across all groups (electricians, mechanics, hoist operators and shaft inspectors) in the same sitting which proves beneficial in the discussions.

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Case Study: Provide mechanical and electrical inspection for five hoisting plants at one site

Requirements: Supply mechanical and electrical hoist plant inspection including NDT of critical components on multiple hoist plants at a single site.

A number of different hoist plants are inspected for mechanical and electrical deficiencies based on local codes and regulations. These inspections cover non destructive testing (NDT) of critical components in the hoisting plant and welds on the hoist itself. Running tests are also performed to ensure the hoist and brake control systems adhere to the local Labour regulations. Deceleration tests are completed to determine if the Emergency Stops for the hoist satisfy the rates established in the regulations.

A detailed report is provided with all items that were found during the hoist plant inspection and then an action plan is setup to address these items with site.

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Case Study: Replacement guide rope into modified vent shaft with limited access

Requirements: Develop a plan to safely remove existing rope and install new guide rope.  The work was to be performed at an egress shaft which had been modified to act as a primary downcast ventshaft for the mine site.

A detailed procedure was developed in co-operation with site and contractor personnel.  The procedure was prepared to limit exposures and mitigate risks presented by restricted work spaces and limited communications. 

Engineering drawing packages were prepared for rigging fixtures to be installed in the headframe for rope handling.  The fixtures were installed within existing structural constraints created by fan shrouding in the headframe and the limited access to the shaft.

Existing winch equipment was evaluated and tested.  New rope anchors were designed and installed to allow maximum removal of the rope from the drum during moves.

On-site support was provided for all critical phases of the project including development, design, fixture installation and removal and installation of the rope.

Guide Rope Replacement engineering is only part of our available services, check out our other services here:
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Case Study: Replacement of a roller element bearing on the main shaft of a large double drum hoist

Requirements: The bearing inboard of a direct-drive motor on the main shaft of a large hoisting plant experienced premature failure.  A plan was required to remove the large roller element bearing while minimizing downtime on the only production hoist at the mine site. 

A detailed procedure was developed to safely replace the bearing while minimizing interruptions to the operation of the mine site.  The procedure detailed removal of the large 1,000 hp direct drive AC motor stator and rotor as well as lifting the drum assembly to allow removal of the bearing from the housing.

Detailed drawing packages were prepared for fixturing and rigging to lift the motor rotor and hoist drum assembly.  Specialized hydraulic tooling was specified to evenly raise the hoist assembly.  Procedures provided detailed listings of all rigging equipment and specialty tools as well as target values for re-installation of the bearing and other hoist mechanicals. 24-hour on site support was provided during the removal to support heavy lifts and ensure the return of the hoist to safe operating conditions prior to resuming normal operations.

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Case Study: Replacement procedures and fixture design for replacing head ropes at flagship mining installation

Requirements: Development of a procedure to replace the head ropes on three large hoisting plants.  Fixturing and general procedure was to be prepared to maximize commonalities between the three hoist plants.

A detailed procedure was developed within customer requirements to limit exposures and mitigate the risks of handling large ropes.  The procedure included sketches, tooling lists and target values to provide simplified reference during completion of the procedure.

Detailed drawing packages were developed for common handling fixtures (deflection sheaves, rope anchoring) designed for use at all three hoisting plants.  A level winder was designed to control rope spooling on and off of the rope reels. On-site support was provided during installation of the fixturing and completion of the first rope change. 

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Case Study: Replacement hydraulic bearing lubrication for plain bearings

Requirements: Replace a hydraulic bearing lubrication system to improve oil distribution and condition monitoring.

The new bearing lubrication system was designed to allow precise flow of oil to each individual bearing housing port and improve distribution across the face of the journal.  Overall oil flow was increased to optimize wedge development and maximize bearing life.  The system provided monitoring of overall oil flow as well as oil flow to each individual bearing port.

The system was custom manufactured on separate containment skids to allow the system to be moved into the basement of the hoist room through existing access hatches.  The tank included control and monitoring of oil temperature, levels and filtration.

Site support was provided during system installation to assist with tube routing, electrical integration into the existing control system as well as during set-up, commissioning and testing.

Hoist Bearing Lubrication Systems are only part of our available services, check out our other services here:
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Case Study:  Addressing Cracks in Hoist Drums

Requirements: Our customer reported that cracks were presenting in their double drum hoist and the customer needed to understand what was causing the cracks and if there were options to address the cracks.

We made a site visit to review the hoist, the drum structure, the existing cracks and to take field measurements.  The field measurements were then used to create an accurate 3D model of the drum for a Finite Element Analysis (FEA) load review.

The results of the FEA allowed us to understand how the structure was loaded which in turn helped us to determine how the cracks in the structure developed.  Additional analysis was completed to see if the existing structure with the cracks was suitable for the existing operational loads.  As previous analysis projects have indicated, it is not out of the ordinary for some cracks in the drum to develop.  It is case by case but sometimes the structure wants to crack to relieve itself and once cracked they do not propagate further.

To confirm the results of the FEA, strain gauge testing was completed on the existing drums.  This allowed us to confirm that the results of the FEA were accurate.

From the testing and analysis, a list of recommendations to address the cracks was presented and reported to site.  Recommendations included practical short-term steps to slow the crack propagation and permanent long term solutions to address the problem.

Hoist Drum FEA’s are only part of our available services, check out our other services here:
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Case Study: Add pinion brake to existing double drum service hoist

Requirements: The site was wanting to perform single drum man travel during emergencies. The hoist was a double drum hoist with a single motor and was not equipped with a pinion brake. A pinion brake needed to be added to the existing hoist without affecting the current hoist/motor locations. This pinion brake would ensure that two brakes were always available during single drum operation.

A pinion brake coupling was designed to replace the existing motor coupling. Calipers were fitted to custom designed stands which allowed for mounting between the existing hoist motor and bull gear.

Due to space limitations a specially design pump unit was supplied that allowed for mount in the available space.

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