The San Xavier Mine - Hoist Commissioning

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THE

SAN XAVIER

MINE:

HOIST

COMMISSIONING

By

DANA

IONET

SPECHT

A

Thesis

Submitted

to the

Honors College

In Partial

Fulfillment

of

the

Bachelors

of

Science

degree

With

Honors

in

Mining

Engineering

THE

UNTVERSITY

OF

ARIZONA

MAY 2OI1

Dr

Mary Poulton

DeparEnent

of

Mining

and Geologrcal

Engineering


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STATEMENT

BYAUTHOR

This

thesis has

bee4

submitted in

partial

fulfilknent of

requirements

for

a

degree

at The

University

of Arizona

and

is

deposited

in the

University Library

to be

made

available

to

boriowers

under rules

of

the Library


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Statement of Individual Work

Dana Specht: Mine Leader. San Xavier Mine Manger.

Responsible for coordinating the project with the mine.Also responsible for coordinating and delegating team

duties at the San Xavier Mine.

Scott Shields: Contracting Leader. San Xavier Associate

Engineer. Responsible for coordinating with contractors

and setting up meetings.

Stephenie Mirka:

Responsible for following project

requirements and insuring all research and team

deadlines were met.

Andrew Swazey: Responsible for technical data and

visual imaging.


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Contents

Executive Summary ......................................................................................................................... 1

Introduction .................................................................................................................................... 2Scope of Work ................................................................................................................................. 3

Background ..................................................................................................................................... 4

Mine History ................................................................................................................................ 4

Hoist History ................................................................................................................................ 5

Current Hoist ........................................................................................................................... 5

Refurbished Hoist .................................................................................................................... 7

Usage ........................................................................................................................................... 8Communication ........................................................................................................................... 9

San Xavier Hoisting Emergency Procedures .......................................................................... 10

RopeRanger Autonomous System .......................................................................................... 11

Rope .......................................................................................................................................... 11

Cameras ..................................................................................................................................... 12

Utilities ...................................................................................................................................... 13

Schedule ........................................................................................................................................ 13Fall Schedule .......................................................................................................................... 14

Spring Schedule ..................................................................................................................... 14

Implementation Schedule ..................................................................................................... 15

Budget ........................................................................................................................................... 16

Hoist Upgrade Costs .................................................................................................................. 16

Commissioning Costs................................................................................................................. 17

Design ............................................................................................................................................ 18Risk Assessment ........................................................................................................................ 18

Opportunities and Challenges ................................................................................................... 20

Hoisting calculations ................................................................................................................. 22

Implementation ......................................................................................................................... 23


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iv

San Xavier Hoist Operating Hardware Manual ............................................................................. 23

Future Work .................................................................................................................................. 23

Conclusion ..................................................................................................................................... 24

References .................................................................................................................................... 27

Appendix A - San Xavier Mine Operating Procedures .................................................................. 28

Appendix B - Existing and Proposed Electrical Loads ................................................................... 30

Appendix C - Schedule and Budget ............................................................................................... 32

Appendix D - Risk Analysis ............................................................................................................ 35

Appendix E - Applicable MSHA Regulations ................................................................................. 37

Appendix F - Applicable OSHA Regulations .................................................................................. 44

Appendix G - Applicable Arizona Mining Regulations .................................................................. 46

Appendix H - Stantec Proposal ..................................................................................................... 47


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Executive Summary

The San Xavier Mining Laboratory (SX) outside of Tucson, Arizona, is a one-of-a-kind venue,

partly due to its working shaft. The SX has provided many mining engineering students with

vital experience before moving forward with their career. Capital has been raised to improve

the shafts hoisting system, and that capital will go towards the implementation of newly placed

hoisting equipment. This implementation will improve the functionality and safety of the hoist

system.

The project consists of three major parts: implementation and engineering verification of the

physical hoist system, implementation of automated hoist controls, and installation of a skip

viewing system. Besides the main project team, the project will include coordination with three

outside groups. The groups involved include Stantec Consulting Services for engineering

verification, SafeHoist representatives to assist with software implementation, and CCT &

Associates to assist with camera system installation. Implementation of the tangible pieces of

the project is to commence following administrative contract verification and signing. A budget

of approximately $15,900 has been estimated for the project. A general implementation

schedule was developed apart from the overarching project schedule to allow for any

unexpected administrative delays out of the project teams control.

At the time of this writing, the newly installed hoist is scheduled to be wound and attached to

the skip. This piece of the project was recently authorized and will be completed by the project

team.


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Introduction

In any industry, safety should come first. The mining industry is no different. A lack of safety

will inhibit the amount of production that operating mines possess. Similarly, a research and

learning facility needs to operate in the same manner, in order to fulfill its purpose of

education. The SX, owned by the University of Arizona, utilizes the No. 6 shaft to train mining

engineering students in removing equipment, muck, and injured persons in the case of an

emergency. Although safe practices may be part of the culture within a mine site, hazards can

still exist. Undeniably, mine shafts and hoists are inherently dangerous if a malfunction were to

occur.

With the advancement of new technology, it is now possible to reduce the risks that hoisting

presents. The SafeHoist RopeRanger system can provide sensors and detectors to improve

the safety of working hoisting equipment. These sensors are installed on the hoist rope. The

detectors report the acceleration, oscillation, and tension of the rope. Additionally, this system

allows the operator to monitor any possible slack in the rope and ensures that the safety factor

remains constant. Shaft changes can be detected, as well.

Prior to installation of the SafeHoist system, a newly purchased hoist rope will be wound by a

team of undergraduate, design students at the San Xavier Mining Laboratory. This team has

developed a project management plan to refurbish the existing hoist by proposing safety

enhancements and automated hoisting controls. In addition to the installation of the

RopeRanger, a Lily Simplex Overspeed and Overwind hoist controller will be implemented.

Finally, the team has proposed that previously donated cameras be installed along the depth of

the shaft, in order to monitor the skip by a use of a BARCO multiple I/O port Central Processing

Unit (CPU).

These components of the proposed refurbishment require outside engineering professionals to

monitor the installation of said components, as well as ensure their reliability. The entirety of

this project will be performed with funds which have been allocated from the Universitys

Mining Engineering Department. Upon completion, the mines currently working shaft will

further accentuate the unique qualities of this underground, research facility. It will provide


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students and other visitors the opportunity to obtain knowledge about a mine shaft and hoist,

while working with improved safety conditions and advanced technological systems.

Scope of WorkThe SX utilizes a shaft and hoisting system to both lower and raise mining and research equipment,

to remove earthen material from two lower levels, and to provide emergency rescue hoisting if

necessary. Currently, the operating system consists of a pneumatically driven drum and is manually

operated from an outdoor station.

The project team proposes safety enhancements and automated hoisting controls for the San Xavier

mine. The project will include hoist engineering calculations, system integration and component

compatibility investigations, and implementation of three systems:

1.) A donated SafeHoist RopeRanger autonomous system.

2.) An existing Lily Simplex Overspeed and Overwind Hoist Controller.

3.) Installation of a skip viewing system along the depth of the shaft.

Figure 1: San Xavier Hoist Commissioning

A newly purchased hoist rope would be wound as part of the refurbishment. Creation of an

operating manual and training procedure would also be within the scope of the proposed project.

The timeline for completion is two months, and will require approximately $15,900 in funding.

External sources of engineering and hoisting expertise are required to complete this project. All


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safety calculations will be reviewed by licensed engineers prior to making in-field modifications to

the existing system.

An electrical engineer will be required to confirm if the existing electrical system will be sufficient

and to ensure compatibility with the safe hoist system. A refurbished Lily Simplex Controller has

been installed at the mine; however, it has not been placed into service. A Safetronics field

representative will be required to integrate the SafeHoist system and to aid in the removal of the

current hoisting components upon commissioning of the system. A professional hoisting engineer

will be necessary to oversee the hoist rope winding and to approve all hoisting calculations

completed under the scope of the project.

Donated camera system components will be integrated with a BARCO multiple I/O port CPU and

screen to increase skip monitoring capabilities. Project team members will be required to install the

cameras and monitoring system. A CCT & Associates representative will be required for system

programming and camera integration with the CPU.

In order to decrease the workload of outside engineers and personnel, the project team will

calculate hoist engineering data, coordinate planned work, and complete installation of the various

hoist system components. The project team will also produce an operating manual and implement a

training plan for new hoist operators.

Background

Mine History

The San Xavier Mining Laboratory is a unique resource that allows students to gain leadership

and problem solving skills with hands-on experience running a fully operational, underground

mine. The University of Arizona Department of Mining and Geological Engineering has

operated the mine since 1958. In 1975, the University of Arizona assumed full ownership of the

zinc, lead, silver, and copper operation from Anamax Mining Company. The property is

comprised of over 90 acres, featuring a mine training and operations facility, a hoist house and

headframe, and work and lay down areas. Located approximately 23 miles south of Tucson,

Arizona, the mine is part of a closed network of mine workings surrounding the No. 6 Shaft.


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Figure 2: San Xavier Mine, 1978

The SX is currently the only mining laboratory in the United States with a working vertical shaft.

Three underground levels are currently operational, including an adit level and two working

levels at depths of 100 feet and 150 feet accessible from the shaft. Primarily a drill-blast-muck

operation, the mine is maintained by university students. This future workforce is heavily

involved in the operations of the SX as student leaders and volunteers spend weekly eight hour

shifts developing the mine and their skill-set. The facility is used for course work from many

different disciplines of education at the University of Arizona and also provides research

opportunities for educational, private, and commercial partners. For these reasons, the SX has

been recognized by the International Society of Mine Professionals for its dedication to

advancing safety and health in the mining industry.

Hoist History

Current HoistThe hoist currently in use at the SX consists of a small, pneumatically powered, Gardner-Denver

air tugger and a 3/8 inch rope, as shown in Figure 2. At optimum conditions, the air tugger

maintains a 1.5 ton load capacity. This capacity has gradually been reduced due to infrequent

maintenance and constant exposure to the elements. Although normal production


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requirements do not exceed this capacity, the hoist is occasionally required to lift an Eimco 12B

tracked overshot mucker. The downward acceleration of the overshot mucker exceeds the

rated capacity by several hundred pounds and cannot be controlled by the brake alone. Thus,

lowering the overshot mucker requires the operator to simultaneously employ the break and

the upward hoisting controls to accommodate the weight.

In addition to the inadequacy of the air tugger, the 3/8 inch cable rope is not designed for

hoisting. When lowering the skip to the 150 foot level, the rope permits nearly 4 inches of

stretch, creating a hazard when miners below are on-loading ore carts or equipment. Many

time-consuming incidents have occurred in which ore carts have been tipped onto the skip,

spilling ore and requiring extensive energy to re-right.

Another cause for concern is the noise interference when operating the hoist. Located outside

in close proximity to the air compressor, the hoist operator is unable to hear directions. For this

reason, the hoist operator typically requires an assistant to listen to the bells and relay

directions. This often causes confusion and is potentially dangerous in emergency situations. All

factors considered, the current hoisting system is well below the MSHA required factor of

safety.

Figure 3: Existing Hoist


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Refurbished Hoist

The hoist to be commissioned at the SX was installed as a senior capstone project in 2008. The

hoist and original AC drive were donated from the Silver Valley Mining District of Idaho. A

comparable DC drive motor and 6:2 planetary gear reducer were donated by The National

Institute of Occupational Safety and Health (NIOSH). Additionally, US Gypsum provided the

electrical distribution consoles and the Program Language Controller (PLC). Prior to installation,

the 2008 senior team designed and poured a hoist foundation with a safety factor of 11. During

this time, the hoist components were remachined, while new drum bearings were installed, the

planetary gear reducer and the DC motor were attached to the hoist base, and an emergency

break operated by air pressure was mounted to the hoist. A SafeHoist system and a Lily

Simplex controller with location indicator were attached to the hoist and PLC for future

automation of the hoist. In addition to the hoist, a 5/8 inch, 18 strand cable rope was

purchased. It is important to note that MSHA requires all hoisting components to meet a

minimum safety factor of 7 for hoisting miners. Although the shaft is currently dedicated to

production, the system exceeds the requirements and would be capable of hoisting people in

the future.


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Figure 4: Refurbished Hoist

Usage

The hoist at the SX is dedicated purely to

materials handling. As students spend weekly

shifts at the mine drilling, blasting, and

mucking, they rely on an operator to hoist the

muck to the surface for dumping. Each level

maintains two ore carts, each weighing 1.6

tons when loaded. Other items commonly

hoisted include jack-leg drills, drill steels, rail,

booster fans, air and water lines, and

miscellaneous tools. Without the hoist and a

sufficient operator, advancement underground would not be possible at the mine.

Figure 5: Student Mucking Underground


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Communication

At the SX, a miners undergroundphone system and a bell system for signaling the hoist

operator are the only means of communications between underground personnel and hoisting

operator or engineers. Shaft bells are used as a method of communication between the hoist

engineer and personnel operating the cages and does not require use of the phone if

communications have been made clearly and with complete comprehension. The moving

location of the skip is unavailable and notification of delivery to desired location is made

through the use of the bell system.

Although this works very sufficiently, a need for improvement was recognized as latency occurs

during this communication and the resulting stop or go signal if altered by the attention of the

operator running the current air-tugger system. Adding to the latency of system operation, the

existing operating station is located away from and inside the hoist house. The essential

feature in any signaling system is that the signals be fully understood by both the engineer and

the bell ringer. Any person authorized to use shaft bells must realize that complete and

thorough cooperation is required between the bell ringer and the hoist engineer. If at any time

a signal is misunderstood or understood fully, the operator shall make contact via the phone

system prior to moving the skip. Mine operators must set the brake on the air tugger and walk

to the mine phone system to achieve communications currently. A secondary visual alarm

system has been added to the traditional bell system, because at times the ambient noise of

the air compressor and operating the air-tugger makes hearing the bell almost impossible. The

potential for missing either bell rings or light alarm signals exist while operating the system.

During these circumstances, it is imperative the operator of the hoist make contact with the

requesting bell ringer to ensure accurate and complete communications were made. After

receiving confirmation, the hoist operator could return to the air-tugger and make the

requested skip movements. Once fully commissioned, the mine phone will be located next to

the indoor operation station and will eliminate much of the time lag currently occurring.

Position location of the skip will be made available via a physical location depth gauge and level

indicator, and visual display through the RopeRanger hoisting graphical user interface (GUI).

Electric switches will be located at collar locations to identify skip location and to provide motor


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control commands. A touch screen display will provide location of the skip as well as numerous

other hoist monitoring functions.

San Xavier Hoisting Emergency Procedures

Currently, the only emergency hoisting procedure identified for an operator of the hoist or forrequesting mine operations personnel, is a 7-Bellemergency alarm signal. Upon the

identification of a hazard, potential hazard, or accident during hoisting operations, mine

personnel must ring the bell seven times in succession. The hoist operator should immediately

set the break on the air-tugger halting all further movement of the skip, proceed to the Mine

Phone System and ascertain further information. The existing air tugger system has a single

brake that can be applied while the newly refurbished system will have multiple brakes upon

completion of the installation.

In total, three braking systems are available for normal and emergency operations. A manual

hand assist brake, a fail-safe air/electric dual caliber brake, and the Lily Overspeed Controller.

The Lilly Overspeed Controller will serve as the operating braking system and is controlled via

the SafeHoist operating control panel or via an emergency stop push button. The manual

hand assist braking lever shall only be used in the event of complete failure to either the air

brake or the Lily Overspeed Controller. Its primary function is to be a parking brake and is to be

engaged when the skip is to remain at a set location for extended time periods. The newly

installed hoist now has a fail-safe air brake installed on the drum and will be the primary

braking component during an emergency. The primary brake is pneumatically and

electronically controlled. During the event of either a power loss to the motor, a loss of air in

the compressed lines, or from a general all stop called for by an operator during emergency

shut down scenarios, a dual caliber brake pad will cease movement of the drum. In the event

of over-travel, protection to the hoist and skip will be provided by an electric switch installed on

the head frame and at defined stations in the shaft.

Once the system is complete, all controls for the hoist operation including shaft location

dispatch will occur via the SafeHoist operator station controller. Until this work has been

completed, a manual operation mode is also available for use during hoisting events and can be


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engaged for raising and lowering of the skip. Controls for manual operation are located on the

controller station panel display. Braking during manual operation is achieved by the

engagement of the caliper brake pads via the all stop emergency button. Speed of the hoist

must be monitored closely by an authorized user and special attention must be paid to

eliminate overpowering of the brake. To perform manual movement operations, the SafeHoist

control panel, motor controller, and main power supply to the hoist must be energized.

RopeRanger Autonomous System

The RopeRanger hoist monitoring system is

a start of the art multi-sensor monitoring system

used to track critical operational and safety

components during mine hoisting. Monitoring is

obtained real time and can be displayed on a touch

screen operator SafeHoist display and control

station. The system is self contained and

environmentally protected against dust and

contamination during use. It uses a 16 bit analog to digital converter while monitoring rope

tension, vibration, acceleration, speed, slack, overload and over-distance parameters. To ease

requirements for installation, the system utilizes wireless radios as to not interfere with existing

wire rope hardware and equipment. The RopeRanger system monitors tension sensitivity to

approximately 0.001% and is well suited for the 5/8 inch cable installed on the refurbished hoist

and drum assembly.

Rope

The 5/8 inch, 18 cable rope purchased by the San Xavier mine

must be wound by a licensed hoisting engineer. As shown in

Figure 7, the placement of the hoist drum was located to

maintain a rope fleet angle less than 1.5 degrees. The current

setup utilizes a 1.3 degree fleet angle to the sheave wheel.

This design factor is important in maintaining the integrity of Figure 7: Fleet Angle

Figure 6: RopeRanger Monitoring Screen


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the drum throughout its operating life. Angles exceeding 1.5 degrees can cause premature wear

and will not utilize the full length of the drum. This new rope has a capacity of 22.5 tons and a

safety factor of 8. All other design factors are shown in Table 1.

Table 1: Rope Specifications

Dead windings 10

Max fleet angle 1.5 degrees

Length 432.3 feet

Minimum strength 40868.1 Lb

Max diameter 5/8 in

Lays/drum width 38.4

Length/wrap 5.9 ft

Layers 1.5

Max tension 5108.5 Lb

Rope angle from horizontal 73.0 degrees

Cameras

A series of Intec wide angle cameras will be installed in the shaft for skip monitoring

capabilities. The cameras have multiple sealed injection cast alloy enclosures and use a Mil-

spec connector to eliminate potential shorting caused in the event of water exposure in the

shaft. There are enough units to place one camera at the collar and a unit at each of the lower

level shaft stations at the 100 foot and 150 foot levels. The hoist operator will now have the

capability to adjust skip position to ensure an appropriate loading platform based upon

visibility. A BARCO multiple I/O port CPU and touch screen display will allow the operator of

the hoist to have multiple views simultaneously or to have a single isolated but larger screen

when necessary. Installation of the cameras will occur after the limit switches for hoist

operation have been installed. CCT & Associates are providing technical expertise for the

installation of the touch screen CPU and for potential integration with the hoist operator

monitoring station.


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Figure 8: Intec Wide Angle Camera and Features

Utilities

Power is supplied to the hoist house via an underground duct bank and terminated in panels

located in the hoist control room. As a result of previous investigations into the connected

versus demand load schedules of supplied power feed and utilization at the SX,

recommendations have been made to upgrade the system in total capacity. It is also

recommended that careful consideration be paid to live current demand when starting motors

at the SX, as a potential for overdraw may exist.

Currently, the mine is supplied with a 200A 3 Phase power feed source; however, it is rated for

400A according to Trico Power. In recent years this system was evaluated by other project

teams. A proposal for ideal power supply was made based upon the following calculations from

recommended electrical feed. An electrical engineer has determined the installation of the

electrical feed sources to the main control panels and PLC cabinets have been installedcorrectly, however, verification of this conclusion could not be ascertained by this project team.

As a result, Stantec Engineering will provide an electrical engineer to perform a job site audit to

ensure there are no hazards to staff and personnel working in the hoist house and hoist control

room. The electrical engineer will also determine the demand versus connected load. These

determinations will ensure the existing power system is capable of handling the startup and

safe operation of the rebuilt hoist.

Schedule

The time table for this project has been an integral part of moving the project forward. While

scheduling setbacks have occurred, reporting and presentation deadlines have remained

unchanged. The project has progressed over an academic year, so the project time table was


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split into two semester schedules. Very little work was completed in the break between the

semesters, due to conflicting personal schedules. The semester time tables can be found in

Appendix A. While work on preparation for the physical implementation of the project has been

mentioned in the schedule, the time table of the physical implementation has been developed

to be independent of the academic schedule.

Fall Schedule

The fall work schedule was used for some parts of the project, but unexpected events caused

problems in completing some of the items on schedule. Additionally, some of the items on the

schedule were not completed due to changes in how the physical implementation would occur.

Changes to the schedule were driven by clarifications in the scope and changes in applicable

Stantec personnel. For administrative reasons, the scope changed from design and

implementation to designing an implementation plan to be executed when time permitted. This

change was due in part to Stantecs loss of Clyde Peppin, the former project mentor. The loss of

Mr. Peppin caused issues with coordination and communication with Stantec representatives,

delaying the implementation process. As a result of those unexpected events, no items

associated with system verification or physical implementation occurred in the fall. Despite

changes to the implementation and design items of the schedule, the project reports and

presentations were able to continue as planned. Initial project outlines and proposals were

completed on schedule, but were later revised as the project scope was clarified. Resource

requirements were defined, allowing for a budget to be created. The resource requirements

remained largely unchanged, but the budget was revised as the roles of the various groups

involved were redefined.

Spring Schedule

Changes in the fall schedule led to the need for revisions in the spring schedule.

Implementation of the project was moved to spring, pending full administrative approval for

the execution of the project. Dates for implementation are included in the spring schedule, but

have been delayed and are subject to further change pending complete final approval. Due to

the revised scope of the project, only one direct meeting with the new main project consultant,

Ed Thomas, was necessary. Ongoing telecommunication was used as necessary instead of direct


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meetings due to a revised and limited scope on the part of Stantec and the fact that Stantec

engineers are located in Phoenix, Arizona. Unlike the variability in timing available for

implementation, reports and presentation elements are to be completed on schedule.

Implementation Schedule

The implementation schedule has been developed to be separable from the academic schedule

due to administrative uncertainty and uncertainty with outside vendor representative

availability. Representative availability is a severely limiting factor in the implementation

process, so the implementation process has been divided into an order of events that must take

place to complete the project. This order of events is shown in Table 2. It is important to note

that the camera implementation process is separate from the hoist implementation process.

Table 2: Implementation Order

Description Order Groups Involved

Hoist Implementation

Electrical review 1 Stantec

Hoisting calculations 2 Stantec, Design Team

Engineering review 3 Stantec

Hoist rope change out 4 Stantec, Design Team

Software implementation 5 SafeHoist, Design Team

Operating manual

documentation

6 Design Team

Camera Implementation

Placement design 1 Design Team

Wiring and installation 2 Design Team

System setup and software

implementation

3 CCT & Associates,

Design Team

Having an implementation order instead of a dated schedule is of great benefit for this project.

Due to the small budget of the project when compared to large commercial mines and the fact

that time spent is an in-kind donation by a University partner, the outside company


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representatives will likely be working on this project only in their spare time. Work will likely

commence on weekends when the groups involved are available, meaning the implementation

will occur in fragments over an extended period of time.

Budget

Hoist Upgrade Costs

Prior to the completion of this hoist upgrade project, other hoist improvement projects have

commenced to that have lead to the final commissioning of the refurbished hoisting system.

Necessary previous projects have included construction of a hoist mounting base, rewiring the

hoist room to accommodate a large hoist motor, and refurbishing and installing the hoist used

in the proposed project. The cost for the rewire project is not included in the report for that

project, therefore the cost for that piece of the overall project is unknown. However, the costs

for the 2008 San Xavier Hoist Upgrade project are known. These costs should be considered

when considering the overall costs sunk into the overarching hoisting system upgrade. The

costs for the 2008 San Xavier Hoist Upgrade project are shown in Table 3.

Table 3Project Costs

Item Cost

Machine Work $9,000

Epoxy $120

Bolts $140 (Shipping, Bolts donated)

Wire Rope $1,200

Electrical $800

Grease $150

Gantry Crane $700

Miscellaneous Equipment Rental $400

Total $12,510


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Commissioning Costs

Project cost is an important piece in overall project management progression, so a cost

schedule has been developed for the hoist upgrade. This cost schedule has been developed on

an all-inclusive basis, taking into account all known major costs from initiation to completion of

the hoist upgrade process.

The project includes coordinating with three major outside sources and winding the hoist rope.

Outside sources consulted in this project include Stantec Consulting Services, who provide

engineering consulting services, SafeHoist, the manufacturers of the hoist controller system,

and CCT & Associates, a solutions consulting group familiar with the camera functionality and

construction. A generalized breakdown of the project costs is listed in Table 4. A full breakdown

of the associated costs can be found in Appendix A.

Table 4General Costs

Description Cost

Stantec

Project Management, Controls $1,353

Site Visit $4,364

Historical Document Review $1,361

Electrical Design Review $1,913

UA Report Review $308

Miscellaneous Fees $3,901

SafeHoist

Site Visit $700

CCT & Associates

Site Visit $1,000

Equipment

Rope Attachments $500

Camera Installation Equipment $500

Total $15,900


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The majority of the costs are associated with consultation with the outside sources, but there

are some equipment costs as well. Costs associated with Stantec are primarily for engineering

services to oversee hoist implementation and verify calculations associated with the hoist

system. The costs associated with SafeHoist are for a company representative to visit the hoist

and assist with the SafeHoist RopeRanger system setup and implementation. Similarly,

representatives of CCT & Associates will need to visit the SX as well to assist in the setup and

installation of the camera system and potential integration with SafeHoist operating systems.

Cost estimates for the CCT and SafeHoist representatives are for flights and hotels only; time

spent working on the project by these representatives will be an in-kind donation. Additional

costs will be associated with winding the hoist rope and the camera installation. The hoist rope

equipment and camera equipment costs have been roughly estimated, but are unlikely to

exceed the costs listed. Costs for winding the rope include the purchase of cable clamps,

thimble, clevis, and safety latch devices.

Considering all the elements of the implementation plan, the estimated cost to complete the

project is $15,900. Financing for the project will be from the University of Arizona Mining

Department budget as funded by the Science Foundation Arizona program. This cost estimate is

lower than the actual value, due to in-kind and other donations by the outside sources

involved. SafeHoist and CCT & Associates are giving in-kind donations by sending

representatives to assist with their respective systems. Services provided by Stantec will not be

donated, but Stantecs cost estimate does include a fifteen percent preferred customer

discount.

Design

Risk AssessmentPrior to project initialization, a Job Safety Analysis was performed on February 12, 2011 to

ensure the teams awareness of all safety hazards present at the San Xavier Mine. This item is

included in the appendix for further reference.


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During the completion of this analysis, both behavioral and hazard checks were made. An

examination of the required documentation and Lock Out/Tag Out/Try Out (LOTOTO)

procedure was completed during this analysis. Also, emergency equipment, such as fire

extinguisher and eyewash station, was located. Several factors were incorporated into the

behavioral analysis. These include positioning all personnel away from moving objects,

ensuring visibility in the area, establishing that no lifting will be required, and making certain

that communication during the project will be properly coordinated. An overview of Personal

Protective Equipment (PPE) that must be worn while in the mining laboratory was discussed.

On the other hand, a hazard check was comprised of identifying other concurrent jobs on-site,

weather issues, and proper lifting equipment, as well as a number of other hazard inspections.

Additionally, a hoist risk analysis was performed in order to assess any risks that could affect

personnel involved in the project. Hazards within the project can affect the maintenance,

construction, and operation of the equipment.

Both mechanical and electrical problems can disrupt the maintenance of the hoisting system.

Many critical tasks exist for reducing these risks. For example, the hoist, sheaves, and rope all

possess the potential for the following mechanical problems. In order to minimize any

potential risks, suspended loads, sources of energy, rotating equipment, and pinch points need

to be identified. Also, other dangers may arise mechanically, in the form of slips, trips, falls,

falls from a height, noise exposure, chemical exposure, falling objects, lack of ventilation,

moving equipment, and flammable substances. In addition to the previously listed risks,

conveyances from the haulage level also includes the possibility of falls from a height in the

shaft, falling rocks in the excavation, and falling items in the shaft. In order to minimize the last

hazard, fall protection should be in place above and below the station.

Electrical maintenance problems may arise through the main power, main drive, control power

and voltage, safety interlocks, and compensation sheaves. Issues with the main power can be

identified as originating from any sources of energy, suspended loads, pinch points, slips, trips,

and falls, falling objects, and falls from heights, as well as noise and chemical exposure.


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Flammable substances, moving equipment, lack of communication, lack of ventilation, security,

and arch flashes are also included in these possible sources of danger.

Hoisting hazards can also impact the construction during the project. Mechanical and electrical

risks include suspended and moving heavy or large loads, sources of energy, rotating

equipment, pinch points, slips, trips, and falls, and falls from heights. In addition, any chemical

exposure, noise exposure, flammable substances, lack of ventilation, falling objects, and mobile

equipment may pose a problem. Finally, workers lacking task-specific skills can affect the

construction that will take place on the hoisting system. Civil hazards consist of the prior issues,

as well as any excavation blasting in the foundation.

Finally, this project may impact the operation of the system. In order to mitigate any hazards

that will affect the operation of the hoist, several resources can be provided on site. Adequate

emergency planning, proper guards on moving equipment, as well as sufficient transportation

for personnel, material, and equipment can minimize any hazards. Also, environmental risks

and ergonomics must be taken into consideration. The design team should ensure that proper

access is available for all equipment and personnel in the working areas.

Opportunities and Challenges

This project has required a solid project management plan to ensure timelines are met and the

project reaches completion by May 2011. It commenced with the knowledge that several risks

would be present. These risks have evolved into challenges over the course of the project

timeline.

Primarily, an unexpected setback occurred during the latter part of January. The project teams

original mentor, Clyde Peppin, left Stantec to pursue opportunities elsewhere. As a result,

Edward Thomas (also from Stantec) became the new Project Manager. Mr. Thomas knowledge

of the hoisting upgrade project was limited at the time. This required him to take time to read

the teams project proposal, as well as find time to travel out to the project site.

In addition, a risk to the completion date has been identified as consultant availability and

engineering support. While the project has an established budget, much of the effort devoted


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to this project comes in the form of donated time and services. All three previously mentioned

external resource requirements have been or are donating time to the project with an

understood agreement of availability to perform. For example, Mr. Thomas is involved in other

various projects for Stantec, which has required him to fit the UA project into his schedule.

Since his office is located in Phoenix, Arizona, it was difficult for him to find time to travel down

to make a preliminary site visit to the San Xavier Mine. This conflict with time resulted in a

delay in Stantec drafting a project proposal for Mr. Ros Hill, the Director of San Xavier Mining,

to approve. This delay in Stantecs work has consequently postponed SafeHoists visit to the

San Xavier Mine. SafeHoist is unable to install their equipment until the rope is wound on the

hoist drum.

Additionally, time commitment for student team members has proved to be a challenge. Since

all four members are enrolled in their final year of their undergraduate career, it has been

difficult to fit meetings into their schedules. The members have commitments with work and

school, and two hold leadership positions at the San Xavier Mine. These demanding schedules

have created difficulties in the organization of team meetings and site visits. Also, as of

December 2010, the academic schedules of the team changed, in accordance with the

Universitys policies. This created further problems when attempting to find agreement among

their schedules. In order to complete the required work by the project deadline, a project

management plan was developed by the team of students. This plan has allowed for some

deviation to the proposed schedule.

During the engineering analysis of existing and proposed hardware, details for compatibility

and capacity will either show compliance or the need for further infrastructure development.

Due to the postponement of many of the projects phases, it has been determined that the

project management plan will be passed on to other students in May 2011, in order that the

project can be completed in the fall semester of 2011.

Just as there are risks that may cause delays, there are also opportunities to expedite the

project in the future. With the involvement of vendors that are engineering professionals as

well as product suppliers, projections for time commitments and for necessary resource


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involvement may become reduced. Stantec engineers are well versed in safe hoisting

techniques and will recognize potential pitfalls, unidentified by the student team. SafeHoist

professionals have installed similar systems globally and could sufficiently reduce the time

requirements for installation. Experts may also recommend colleagues from their past

experiences to assist with the San Xavier Hoist Upgrade Project. One of the positive outcomes

from our change in mentor is that Mr. Thomas is a University of Arizona graduate. As a student

working at the San Xavier Mine, he helped construct the headframe. This has proved to be an

asset, as far as knowledge and time is concerned, since Mr. Thomas is aware of the background

of the mining laboratory.

Another opportunity for success came in the form of donations to the Mining and Geological

Engineering Department. Time, effort, and equipment have already been donated to the San

Xavier mine to enhance the hands-on learning environment. Additional hardware and time

commitments donated to the mine could decrease the amount of external and internal

resources required for successful project completion.

Hoisting calculations

The San Xavier Mine has attempted to upgrade its hoisting system since 1978 when the current

headframe was erected. Since then, multiple hoisting calculations have been conducted to find

an optimum solution in ore handling. The unique situation encountered in 2008 was the

inability to choose the perfect hoist, but instead to optimize the hoist donated to the mine.

Using all calculations with current knowledge enabled the team to accurately confirm or

recalculate the necessary information pertaining to this hoist. Pertinent information regarding

the hoist can be found in Table 5. All correct calculations performed within the last ten years

are available in Appendix G. Through the research and calculations performed by this team, all

components of the hoisting system exceed the minimum factor of safety of 7 set forth by

MSHA.

Table 5Hoist Specifications

Hoist Type Single Drum

Hoist Drum 22.5 in. Diameter


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Hoist Gear 48.0 in. Diameter

Drum Width 24 In.

Drive Gear 4.0 in. Diameter

Dist to sheave H 46.5 Ft.

Dist to sheave V 40.1 Ft.

Lifting on Hoist 4885.4 Lb.Drum RPM 17.0 rpm

Implementation

Once all contracts have been signed and authorization from the University of Arizona

Contracting Services has been given, actual physical implementation of the hoist improvement

project will occur. Primarily, a safety audit and electrical review will be conducted by a small

group of engineers from Stantec. Upon completion of these mandatory items, they willsupervise the student project team in winding the newly purchased rope on the hoist drum,

safely and securely. Subsequently, Mr. Mike Beus from SafeHoist Inc. will install the

RopeRanger and Lily Simplex Controller systems. He will also aid in the removal of the current

hoisting components. Ultimately, volunteers at the student mine will install the cameras along

the shaft, as well as the monitoring system. A representative from CCT & Associates will be

required in order to program the system and integrate the cameras with the CPU.

San Xavier Hoist Operating Hardware Manual

Accompanying this report is an operating manual for the combined components of the

SafeHoist and RopeRanger operating systems. This manual is tailored specifically for the San

Xavier Hoist and will serve as a training guide outlining the safe operating procedures.

Future Work

This project advances the functionality of the hoist greatly, but further work could improve the

functionality of the hoist. These improvements are beyond the scope of this project, but further

projects could bring the hoist systems abilities forward.


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One goal for the hoist system is to become man-rated. Man-rating the hoist would involve two

major projects, re-lining the shaft with non-flammable materials, and changing out the skip for

a man-rated cage. The existing cribbing and guide rails for the skip are all wooden, but law

dictates that shaft lining and guide rails in a man shaft are non-flammable. Another project that

would be required before man-rating is installation of a man cage. The current skip does not

have a surrounding cage, and is not man-rated. To prepare the hoist system for man-rating,

future work would include re-lining the shaft with steel cribbing and installing a steel man cage.

Another goal for the hoist system is to eventually service the entire shaft. Due to problems on

the 250 foot level, the serviced shaft stations only include the 100 foot and 150 foot levels. This

project allows the hoist to reach the 250 level, but the condition of that level is not fully

understood. In order to reach the 250 level, inspection and rehabilitation of the shaft between

the 150 and 250 levels would be required. Additionally, the shaft station would need to be

rehabilitated and have communications extended to that level.

As far as this shaft is concerned, the future projects listed would essentially complete the

functionality of the hoist. The future work mentioned would allow the hoist to carry any normal

load, human or otherwise, and hoist along the entire length of the shaft. Absent sinking the

shaft further or any other type of earthwork, the shaft would be advanced to its maximum

functionality.

Conclusion

The San Xavier Hoist Improvement project, proposed by Team SevenStephenie Mirka, Scott

Shields, Dana Specht, and Andrew Swazey, was a tremendous learning experience. The project

quickly evolved from what we initially perceived to be an engineering design assignment to

what was really a project management learning experience. Throughout the two semester

terms, our mentors Mr. John Fenn and Mr. David Naccarati continually reminded us our

ultimate goal is to manage our work such that if an immediate need to pass on responsibilities

for completion of the project occurred, another qualified team could resume work and

successfully finish the job.


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A major change to our project was the deviation from an engineering design to commissioning.

Initial perspectives of the work was that our team would be required to investigate current

hoisting conditions, calculate hoist and load parameters, and implement changes as required.

Although this is true in respects, we quickly realized much forethought and work to accomplish

these goals had already culminated.

Much of the time we spent developing this project was investigating what had been done

before we assumed responsibility for completing the hoist improvements. Other work crews in

years passed had culminated their design projects by completing not only technical reports, but

also providing a product. Unfortunately, the data and the respective final reports were not

stored in locations available to our team. Many hours were spent tracking down data from the

past 30 years that are essential for the completion of our specific goals. Not only would our

investigations require tracking down this information on site at the SX Laboratory and the

University of Arizona Mining and Geological Engineering Department, our search spanned to

Idaho, Nevada, Montana, California, and Washington. The resulting finds of material were

astounding in that Team Seven realized our project was beginning a transition from design to

commission.

A major challenge to this project has been the continual timeline setbacks as a result of

commitment and coordination with consulting engineers. Although design work for the hoist

change-out had already been completed by students, this information had to be transferred to

professionals and reviewed for safety. The cause for delay throughout the past seven months

has been a unique series of events including a change in mentor, waiting time for the right

person to be available when needed, and the extended wait while project proposals are

reviewed, revised, and ultimately approved. Once completed, the potential contract then had

to be processed through the University of Arizona Contracting Services group. At this time we

are still waiting for a signed contract to be delivered so that the design work can be completed

safely and efficiently. In addition, commitments to perform much of the outside consulting

work under in-kind donations places our priority below money making jobs. As an industry

partner and a friend to the University, these companies are doing as much as possible to help.


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References

Birbeck, Scott, Philip Requadt, and Erron Winsor. SX Hoist Upgrade: Replacing the Hoist at the

San Xavier Student Mine and Research Laboratory. Rep. 2008. Print.Brokenshire, Peter, and Susan Andersen, eds. Hoist and Haul 2010 Proceedings of the

International Conference on Hoisting and Hauling.Littleton: Society for Mining

Metallurgy, 2010. Print.

Code of Federal Regulations, Mineral Resources, National Archives and Records Administration

30 (1997). Print.

"Crosby Clips: Warnings and Application Instructions for Wire Ropes." 2008. The Crosby Group,

Inc.Featherston, John, Steven Bastian, and Tim George. The San Xavier Re-Wire Project. Rep. 2006.

Print.

Featherston, John. The San Xavier Re-Wire Project. Rep. 2005. Print.

Hartman, Howard L., ed. SME Mining Engineering Handbook. 2nd ed. Vol. 2. Littleton: Society

for Mining, Metallurgy, and Exploration, 1992. Print.

Peppin, Clyde. "Hoist Risk Review Notes." 1 Oct. 2010. E-mail.

Phelps Dodge Corporation, Copper Queen Branch, Mechanical Department. Code of Safe

Practice for Hoist Engineers(1969). Print.

San Xavier Mining Laboratory. SX Safety Manual. The University of Arizona.

Walker, Jr., W. Dan, and R. W. Stahl. "Recommended Procedures for Mine Hoist and Shaft

Installation, Inspection, and Maintenance." Bureau of Mines Information Circular8031

(1961). Print.


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Appendix A - San Xavier Mine Operating Procedures

Safe Hoist Operating Procedures

1. Only authorized persons shall be in hoist rooms or hoist cabs.

2. Personnel shall not ride loaded skip decks, cage decks, or buckets with muck, supplies,materials, or tools other than small hand tools.

3. When a manually operated hoist is used, a qualified hoist operator shall remain within

hearing of the telephone or signal device at all times while any person dependent on

that hoist is in the mine.

4. Only experienced hoist operators shall operate a hoist except in case of emergency and

when new operators are being trained.

5. When personnel are hoisted in buckets, rope speed shall not exceed 500 ft/min andshall not exceed 200 ft/min when approaching the intended station or stopping point.

***Note: The hoistman shall respond to call signals for a cage, before presenting the cage to a

person on a level. Until the hoistman has responded to a signal, thereby acknowledging the

receipt of that signal, no person will attempt to signal on the shaft bell system, nor shall any

person attempt to load a cage until the hoistman has acknowledged the receipt on the

squawker.

Hoist Bell Signals - Hoist Operators Guide

Cage Position Adjustment Signals:

Slow Bells Mean Move Cage Slowly

1 Bell - Stop Immediately

2 Bells - Lower Cage

3 Bells - Raise Cage

General Communication Signals:

5 Bells - Turn Air On/Off

7 Bells - Go to Mine Phone Immediately - Possible Emergency

Surface Cage Dispatching Signals:

1 Long Bell + 1 Bell + 1 Bell - Send Cage to Shaft Collar

1 Long Bell + 1 Bell + 2 Bells - Send Cage to 100 Level

1 Long Bell + 1 Bell + 3 Bells - Send Cage to 150 Level


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1 Long Bell + 1 Bell + 4 Bells - Cage Released from Collar

100 Level Cage Dispatching Signals:

1 Long Bell + 2 Bells + 1 Bell - Send Cage to Shaft Collar

1 Long Bell + 2 Bells + 2 Bells - Send Cage to 100 Level1 Long Bell + 2 Bells + 3 Bells - Send Cage to 150 Level

1 Long Bell + 2 Bells + 4 Bells - Cage Released from 100 Level

150 Level Cage Dispatching Signals:

1 Long Bell + 3 Bells + 1 Bell - Send Cage to Shaft Collar

1 Long Bell + 3 Bells + 2 Bells - Send Cage to 100 Level

1 Long Bell + 3 Bells + 3 Bells - Send Cage to 150 Level

1 Long Bell + 3 Bells + 4 Bells - Cage Released from 150 Level

***Note: Hoist Operator will not move cage unless all bell signals are understood and a signal

has been received from both the sending and receiving shaft stations.


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Appendix B - Existing and Proposed Electrical Loads

Existing Electrical Capacities:

Entire Property 480V, 3, 200A

Hoist House 480V, 3, 100A

Surface Substation 480V, 3, 100A

Existing Electrical Loads:

Hoist House

Operation Volts (V) Phase () Full Load Amperage (A)

Welder 480 3 Rated 50A

Grinder 110/120 1 15

Drill Press 110/120 1 15

Band Saw 110/120 1 5

Cap Lamp Chargers 220/240 1 30

General Receptacles 110/120 1 Rated 60A (20A X 3 circuits)

General Lighting 110/120 1 Rated 15A

Underground Circuit 110/120 1 Rated 20A

(Bells, Lighting, Outlets)

Security Light 110/120 1 15

Radio 110/120 1 1

Total Full Load Amps 131

Surface Substation


100' & 150' Ventilation 480 3 15


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Adit Level Ventilation 480 3 15

100' Level 3 Electrical 480 3 15

Adit Level Electrical 480 3 15

Total Full Load Amps 60

Existing Total Full Load Amps (Entire Property) 191

Proposed Electrical (Rating) Amperages:


Change Room / Office 480 3 200

Electric Compressor 480 3 125

Decline Ventilation Fan 480 3 125

Adit Level 480 3 60

100' Level 480 3 60

150' Level 480 3 60

Hoisting System 480 3 125

Total Proposed (Rating) Amperage 755

453

(Figure on 60% of full load at any given time)

Total Needed Electrical Capacity 567.6 600A


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Appendix C - Schedule and Budget


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Appendix D - Risk Analysis


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Appendix E - Applicable MSHA Regulations

30 CFR 57.16011 - Riding hoisted loads or on the hoist hook.

Persons shall not ride on loads being moved by cranes or derricks, nor shall they ride the

hoisting hooks unless such method eliminates a greater hazard.

30 CFR 57.16017 - Hoisting heavy equipment or material.

Where the stretching or contraction of a hoist rope could create a hazard, chairs or other

suitable blocking shall be used to support conveyances at shaft landings before heavy

equipment or material is loaded or unloaded.

30 CFR 57.19000 - Application.

(a) The hoisting standards in this subpart apply to those hoists and appurtenances used for

hoisting persons. However, where persons may be endangered by hoists and appurtenances

used solely for handling ore, rock, and materials, the appropriate standards should be applied.

(b) Standards 57.19021 through 57.19028 shall apply to wire ropes in service used to hoist--(1) Persons in shafts and slopes underground;

(2) Persons with an incline hoist on the surface; or

(3) Loads in shaft or slope development when persons work below suspended loads.

(4) These standards do not apply to wire ropes used for elevators.

(c) Emergency hoisting facilities should conform to the extent possible to safety requirements

for other hoists, and should be adequate to remove the persons from the mine with a minimum

of delay.

30 CFR 57.19001 - Rated capacities.

Hoists shall have rated capacities consistent with the loads handled and the recommended

safety factors of the ropes used.

30 CFR 57.19002 - Anchoring.

Hoists shall be anchored securely.

30 CFR 57.19003 - Driving mechanism connections.

Belt, rope, or chains shall not be used to connect driving mechanisms to man hoists.

30 CFR 57.19004 - Brakes.

Any hoist used to hoist persons shall be equipped with a brake or brakes which shall be capableof holding its fully loaded cage, skip, or bucket at any point in the shaft

30 CFR 57.19005 - Locking mechanism for clutch.

The operating mechanism of the clutch of every man-hoist drum shall be provided with a

locking mechanism, or interlocked electrically or mechanically with the brake to prevent

accidental withdrawal of the clutch.


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30 CFR 57.19006 - Automatic hoist braking devices.

Automatic hoists shall be provided with devices that automatically apply the brakes in the

event of power failure.

30 CFR 57.19007 - Overtravel and overspeed devices.

All man hoists shall be provided with devices to prevent overtravel. When utilized in shafts

exceeding 100 feet in depth, such hoists shall also be provided with overspeed devices.

30 CFR 57.19008 - Friction hoist synchronizing mechanisms.

Where creep or slip may alter the effective position of safety devices, friction hoists shall be

equipped with synchronizing mechanisms that recalibrate the overtravel devices and position

indicators.

30 CFR 57.19009 - Position indicator.

An accurate and reliable indicator of the position of the cage, skip, bucket, or cars in the shaft

shall be provided.

30 CFR 57.19010 - Location of hoist controls.

Hoist controls shall be placed or housed so that the noise from machinery or other sources will

not prevent hoistmen from hearing signals.

30 CFR 57.19011 - Drum flanges.

Flanges on drums shall extend radially a minimum of 4 inches or three rope diameters beyond

the last wrap, whichever is the lesser.

30 CFR 57.19012 - Grooved drums.Where grooved drums are used, the grooves shall be of suitable size and pitch for the ropes

used.

30 CFR 57.19014 - Friction hoist overtravel protection.

In a friction hoist installation, tapered guides or other approved devices shall be installed above

and below the limits of regular travel of the conveyance and arranged to prevent overtravel in

the event of failure of other devices.

30 CFR 57.19017 - Emergency braking for electric hoists.

Each electric hoist shall be equipped with a manually-operable switch that will initiate

emergency braking action to bring the conveyance and the counterbalance safely to rest. This

switch shall be located within reach of the hoistman in case the manual controls of the hoist

fail.

30 CFR 57.19018 - Overtravel by-pass switches.

When an overtravel by-pass switch is installed, the switch shall function so as to allow the


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conveyance to be moved through the overtravel position when the switch is held in the closed

position by the hoistman. The overtravel by-pass switch shall return automatically to the open

position when released by the hoistman.

30 CFR 57.19021 - Minimum rope strength.

At installation, the nominal strength (manufacturer's published catalog strength) of wire ropes

used for hoisting shall meet the minimum rope strength values obtained by the following

formulas in which "L" equals the maximum suspended rope length in feet:

(a) Winding drum ropes (all constructions, including rotation resistant).

For rope lengths less than 3,000 feet: Minimum Value=Static Load x (7.0--0.001L)

For rope lengths 3,000 feet or greater: Minimum Value=Static Load x 4.0.

(b) Friction drum ropes.

For rope lengths less than 4,000 feet: Minimum Value=Static Load x (7.0--0.0005L)

For rope lengths 4,000 feet or greater: Minimum Value=Static Load x 5.0.

(c) Tail ropes (balance ropes).

Minimum Value=Weight of Rope x 7.0

30 CFR 57.19022 - Initial measurement.

After initial rope stretch but before visible wear occurs, the rope diameter of newly installed

wire ropes shall be measured at least once in every third interval of active length and the

measurements averaged to establish a baseline for subsequent measurements. A record of the

measurements and the date shall be made by the person taking the measurements. This record

shall be retained until the rope is retired from service.

30 CFR 57.19023 - Examinations.

(a) At least once every fourteen calendar days, each wire rope in service shall be visually

examined along its entire active length for visible structural damage, corrosion, and improper

lubrication or dressing. In addition, visual examination for wear and broken wires shall be made

at stress points, including the area near attachments, where the rope rests on sheaves, where

the rope leaves the drum, at drum crossovers, and at change-of-layer regions. When any visible

condition that results in a reduction of rope strength is present, the affected portion of the

rope shall be examined on a daily basis.

(b) Before any person is hoisted with a newly installed wire rope or any wire rope that has not

been examined in the previous fourteen calendar days, the wire rope shall be examined in

accordance with paragraph (a) of this section.

(c) At least once every six months, nondestructive tests shall be conducted of the active length

of the rope, or rope diameter measurements shall be made--

(c)(1) Wherever wear is evident;

(c)(2) Where the hoist rope rests on sheaves at regular stopping points;


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(c)(3) Where the hoist rope leaves the drum at regular stopping points; and

(c)(4) At drum crossover and change-of-layer regions.

(d) At the completion of each examination required by paragraph (a) of this section, the person

making the examination shall certify, by signature and date, that the examination has been

made. If any condition listed in paragraph (a) of this section is present, the person conductingthe examination shall make a record of the condition and the date. Certifications and records of

examinations shall be retained for one year.

(e) The person making the measurements or nondestructive tests as required by paragraph (c)

of this section shall record the measurements or test results and the date. This record shall be

retained until the rope is retired from service.

30 CFR 57.19024 - Retirement criteria.

Unless damage or deterioration is removed by cutoff, wire ropes shall be removed from service

when any of the following conditions occurs:

(a) The number of broken wires within a rope lay length, excluding filler wires, exceeds either--

(a)(1) Five percent of the total number of wires; or

(a)(2) Fifteen percent of the total number of wires within any strand.

(b) On a regular lay rope, more than one broken wire in the valley between strands in one rope

lay length.

(c) A loss of more than one-third of the original diameter of the outer wires.

(d) Rope deterioration from corrosion.

(e) Distortion of the rope structure.

(f) Heat damage from any source.

(g) Diameter reduction due to wear that exceeds six percent of the baseline diametermeasurement.

(h) Loss of more than ten percent of rope strength as determined by nondestructive testing.

30 CFR 57.19025 - Load end attachments.

(a) Wire rope shall be attached to the load by a method that develops at least 80 percent of the

nominal strength of the rope.

(b) Except for terminations where use of other materials is a design feature, zinc (spelter) shall

be used for socketing wire ropes. Design feature means either the manufacturer's original

design or a design approved by a registered professional engineer

(c) Load end attachment methods using splices are prohibited.

30 CFR 57.19026 - Drum end attachment.

(a) For drum end attachment, wire rope shall be attached--

(1) Securely by clips after making one full turn around the drum spoke;

(2) Securely by clips after making one full turn around the shaft, if the drum is fixed to the shaft;


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Man cages and skips used for hoisting or lowering employees or other persons in any vertical

shaft or any incline shaft with an angle of inclination of forty-five degrees from the horizontal,

shall be covered with a metal bonnet.

30 CFR 57.19055 - Availability of hoist operator for manual hoists.

HOISTING PROCEDURES

When a manually operated hoist is used, a qualified hoistman shall remain within hearing of the

telephone or signal device at all times while any person is underground.

30 CFR 57.19056 - Availability of hoist operator for automatic hoists.

When automatic hoisting is used, a competent operator of the hoist shall be readily available at

or near the hoisting device while any person is underground.

30 CFR 57.19057 - Hoist operator's physical fitness.

No person shall operate a hoist unless within the preceding 12 months he has had a medical

examination by a qualified, licensed physician who shall certify his fitness to perform this duty.

Such certification shall be available at the mine.

30 CFR 57.19058 - Experienced hoist operators.

Only experienced hoistmen shall operate the hoist except in cases of emergency and in the

training of new hoistmen.

30 CFR 57.19061 - Maximum hoisting speeds.

The safe speed for hoisting persons shall be determined for each shaft, and this speed shall not

be exceeded. Persons shall not be hoisted at a speed faster than 2,500 feet per minute, except

in an emergency.

30 CFR 57.19062 - Maximum acceleration and deceleration.

Maximum normal operating acceleration and deceleration shall not exceed 6 feet per second

per second. During emergency braking, the deceleration shall not exceed 16 feet per second

per second.

30 CFR 57.19063 - Persons allowed in hoist room.

Only authorized persons shall be in hoist rooms.

30 CFR 57.19080 - Hoisting tools, timbers, and other materials.

When tools, timbers, or other materials are being lowered or raised in a shaft by means of a

bucket, skip, or cage, they shall be secured or so placed that they will not strike the sides of the

shaft.

30 CFR 57.19081 - Conveyances not in use.

When conveyances controlled by a hoist operator are not in use, they shall be released and the


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conveyances shall be raised or lowered a suitable distance to prevent persons from boarding or

loading the conveyances.

30 CFR 57.19083 - Overtravel backout device.

A manually operated device shall be installed on each electric hoist that will allow the

conveyance or counterbalance to be removed from an overtravel position. Such device shall not

release the brake, or brakes, holding the overtravelled conveyance or counterbalance until

sufficient drive motor torque has been developed to assure movement of the conveyance or

counterbalance in the correct direction only.

30 CFR 57.19090 - Dual signaling systems.

There shall be at least two effective approved methods of signaling between each of the shaft

stations and the hoist room, one of which shall be a telephone or speaking tube.

30 CFR 57.19091 - Signaling instructions to hoist operator.

Hoist operators shall accept hoisting instructions only by the regular signaling system unless it is

out of order. In such an event, and during other emergencies, the hoist operator shall accept

instructions to direct movement of the conveyances only from authorized persons.

30 CFR 57.19093 - Standard signal code.

A standard code of hoisting signals shall be adopted and used at each mine. The movement of a

shaft conveyance on a "one bell" signal is prohibited.

30 CFR 57.19094 - Posting signal code.

A legible signal code shall be posted prominently in the hoist house within easy view of the

hoistmen, and at each place where signals are given or received.

30 CFR 57.6204 - Hoists.

(a) Before explosive material is transported in hoist conveyances--

(1) The hoist operator shall be notified; and

(2) Hoisting in adjacent shaft compartments, except for empty conveyances or counterweights,

shall be stopped until transportation of the explosive material is completed.

(b) Explosive material transported in hoist conveyances shall be placed within a container which

prevents shifting of the cargo that could cause detonation of the container by impact or by

sparks. The manufacturer's container may be used if secured to a nonconductive pallet. Whenexplosives are transported, they shall be secured so as not to contact any sparking material.

(c) No explosive material shall be transported during a mantrip.


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Appendix F - Applicable OSHA Regulations

1926.251(c)

Wire rope.

1926.251(c)(1)

Tables H-3 through H-14 shall be used to determine the safe working loads of various sizes and

classifications of improved plow steel wire rope and wire rope slings with various types ofterminals. For sizes, classifications, and grades not included in these tables, the safe working

load recommended by the manufacturer for specific, identifiable products shall be followed,

provided that a safety factor of not less than 5 is maintained.

1926.251(c)(2)

Protruding ends of strands in splices on slings and bridles shall be covered or blunted.

1926.251(c)(3)

Wire rope shall not be secured by knots, except on haul back lines on scrapers.

1926.251(c)(4)(i)

An eye splice made in any wire rope shall have not less than three full tucks. However, this

requirement shall not operate to preclude the use of another form of splice or connectionwhich can be shown to be as efficient and which is not otherwise prohibited.

1926.251(c)(4)(ii)

Except for eye splices in the ends of wires and for endless rope slings, each wire rope used in

hoisting or lowering, or in pulling loads, shall consist of one continuous piece without knot or

splice.

1926.251(c)(4)(iii)

Eyes in wire rope bridles, slings, or bull wires shall not be formed by wire rope clips or knots.

1926.251(c)(4)(iv)

Wire rope shall not be used if, in any length of eight diameters, the total number of visible

broken wires exceeds 10 percent of the total number of wires, or if the rope shows other signs

of excessive wear, corrosion, or defect.

1926.251(c)(5)

When U-bolt wire rope clips are used to form eyes, Table H-20 shall be used to determine the

number and spacing of clips.
http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1926_0251&src_anchor_name=1926.251(c)http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1926_0251&src_anchor_name=1926.251(c)(3)http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1926_0251&src_anchor_name=1926.251(c)(4)(iii)http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1926_0251&src_anchor_name=1926.251(c)(4)(iii)http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1926_0251&src_anchor_name=1926.251(c)(3)http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1926_0251&src_anchor_name=1926.251(c)


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Table H-20:

1926.251(c)(5)(i)

When used for eye splices, the U-bolt shall be applied so that the "U" section is in contact with

the dead end of the rope.


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Appendix G - Applicable Arizona Mining Regulations

27-348. Shaft stations

Stations or levels shall have a passageway around the working shaft so that crossing over the

hoisting compartments may be avoided. Sumps shall be securely covered. At shaft stations a

gate or guard rail shall be provided and kept in place across the shaft, except when a cage, skip

or bucket is being loaded, but may be temporarily removed for repairs or other operations ifproper precaution is taken to prevent danger to persons. The top of the shaft shall be protected

by a substantial gate or guard rail.

27-351. Hoists; operator; indicator

A. No person addicted to intoxicating liquors or drugs, or under eighteen years of age shall be

employed as a hoisting engineer.

B. All power hoisting machinery used in hoisting from or lowering employees and materials into

mines, except for prospect shafts not exceeding three hundred feet in depth, shall be equipped

with an indicator placed near and in clear view or hearing of the engineer. The indicator shall be

in addition to marks on the rope, cable or drum.C. It is unlawful to hoist or lower persons from or into a mine at a speed greater than fifteen

hundred feet per minute, but the inspector may designate a lesser speed than fifteen hundred

feet per minute in a shaft, if in his opinion a greater speed is unsafe, or a greater speed if in his

opinion particular shafts and hoist conditions so warrant.

27-352. Inspection and construction of hoists

A. Hoisting machinery, cables and sheaves shall be inspected once every twenty-four hours by a

competent person appointed by the operator for that purpose, and the person making the

inspection shall immediately report in writing to the operator all defects found.

B. Ropes or cables used for hoisting purposes shall be of approved quality and manufacture. In

shafts and winzes over two hundred feet deep, wire ropes or cables only shall be used for

hoisting purposes.

C. Head frames where persons are hoisted at a speed of over two hundred fifty feet per minute

and where more than twenty-five persons are employed shall be constructed to allow at least

twenty-five feet above the hoist landing stage in which the cage, skip or bucket can travel freely

in case of an overwind.

27-358. Signaling apparatus

A. Every shaft and each compartment thereof used for hoisting which exceeds fifty feet in

depth, and not exempted in writing by the inspector, shall be provided with an efficient means

of interchanging distinct and definite signals between the top of the shaft and the lowest levelfrom which hoisting is being done, and the various intermediate levels for the time they are in

use.

B. The signaling apparatus shall be either wire or cable actuating a bell, whistle, speaking tube,

telephone, electric or electronic system, or two or more of them.

C. Only those employees and supervisors authorized by the operator shall be permitted to ring

any shaft or station bells.


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Appendix H - Stantec Proposal


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Documents

The San Xavier Mine - Hoist Commissioning