Impala Platinum 4 Rope Koepe Winder Rope-up (Patrick de La Hunt)

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IMPALA PLATINUM IMPALA PLATINUM 4 4 ROPE KOEPE WINDER ROPE KOEPE WINDER

ROPEROPE--UP UP SAFETY SAFETY PREPARATIONPREPARATION

PATRICK DE LA HUNT


INTRODUCTION


INTRODUCTION

Impala Platinum has recently successfully and safely roped up 2 newly installed, 4 rope, man and rock, tower mounted Koepe Winders on the 16# project.

This was the first of Koepe winders installed on Impala Platinum.

This presentation will discuss some safety related matters that were dealt with upfront and during the actual rope up. A detailed rope-up procedure will be presented at this forum at a later stage.


PRESENTATION CONTENTS

Presentation contents

1. Back ground, winder and rope-up equipment details2. Upfront safety preparation3. On site safety considerations4. Photos5. Video clips6. Conclusion


IMPALA 16 SHAFT HEADGEAR LAYOUT

7) Koepe Upper level

3) Service winder sheave Level

2) Tipping level

1) Conveyor level

Bank Level

4) Deflection sheave level

6) Koepe Lower level, brake hydraulics

Personnel Loading level (Sub Bank)

5) Transformer level and Drives

On top, Cooling towers for the water cooled drives


1. Back Ground

This new complex was started in October 2004 and the first stoping and mining operations are expected to start in September 2013 (nine years). This is the second of the new generation shafts that will secure jobs for around 4500 people.

Hoisting 226 ktpm of reef out of a 10 metre diameter shaft. The vent shaft is 6.8 metre in diameter. The skip payload is 25 ton.

The shaft depth is 1675 metres below collar, hoisting 2300 persons per hour with a two deck 300 persons cage (150 persons per deck).

IMPALA 16 SHAFT KOEPE WINDERS ROPE-UP


Back Ground contd.

Considering all the effort over the past nine years and also the future of the shaft, the rope up of the Koepe winders was on the critical path and of utmost importance to be completed on schedule and SAFELY

The initial rope up was planned at 13 days per winder



IMPALA 16#, 4 ROPE KOEPE WINDERS


DETAILS OF WINDING SYSTEM

Man Winder Koepe Rock Winder Koepe

Winding Distance 1601m 1640m

Motor Detail 4300kW @ 57.3 rpm 4300kW @ 57.3 rpm

Drum Diameter 6.5m 6.5m

Brakes 4 Channel Disc Brake, Escort Controlled4 Channel Disc Brake

Escort, Controlled

Conveyance MassCage: 26,5 ton

CW: 42,25 tonSkips: 26,5 ton

Payload 22.5 ton 25 ton

Rope Details 4 Head Ropes and 4 Tail Ropes

Head Ropes: 54 mm Full Lock

Tail Ropes: 59mm Non-spin

Head Ropes: 54 mm Full Lock

Tail Ropes: 59mm Non-spin

Rope Speed 16 m/s 16 m/s


IMPALA 16 SHAFT CROSS SECTION

Cage 26.5t. Payload 22.5t

Skip 25t

Skip 25t

CounterWeight42.25t

Service Cage

Service Cage

West East

North

South



The rope handling equipment used during the rope-up was selected to ensure safe handling whilst installing the ropes.

The 4 head ropes installed simultaneously and the four tail rope ropes were also installed simultaneously from surface.

The following slides will be showing the actual rope up equipment used for the rope-up:


FRICTION WINCH

A mobile 1700 kN Friction winch, designed to handle 6 ropes simultaneously. It will also be used on Impala 17 shaft


DEFLECTION SHEAVES AND COMPRESSION BEAMS


CLAMP AND LFTING DEVICE (CLD) 1700 kN Double sided, four rope clamp and lifting devices (CLD),

one for the rock and one for the man winder

CLIP


MESSENGER WINCHES AND DEFLECTOR SHEAVES


ROPE REELERS


RELIANCE CLAMPS AND ACCESSORIES


Koepe Rope Reelers

Friction Winch

Permanent Deflection Sheaves

Koepe Winder (free-wheeling)

Temporary Deflection Sheaves

Compression Beams & Deflection Sheaves

Messenger Winches

LAY OUT OF ROPE UP EQUIPMENT TO ROPE-UP SAFE!!

CLDs


2. PRIOR SAFETY CONSIDERATIONS

Co-ordination (Several different contactors on board)Contractors involved including Impala:- RSV- FLSmidth- ABB, Local and overseas partners - Murray and Roberts- Shaft Sinkers- Winder Controls/Siemag, Local and German partners- DRATS and WORLEY PARSONSTWP, Involved on the 17# project, use same rope up equipment- (Local and international visitors)


EPCM, Contractor selection and adjudicationVery important to select the correct EPCM contractors to manage the project. Ensure the correct quality controls are in place and are adhered to. Generally you have to demand quality. If you do not have quality your system is not safe.

Designs and ReviewsEnsure the scope of work and specifications are properly detailed and reviewed. It is much easier to rectify matters during reviews than at implementation phase. Greater frontal engineering will ensure better implementation success.Regulations and SANS codes applied.

Hazards identification / Risk AssessmentCombined Risk assessments through out the process was carried out to identify hazards (EPCM, OEM, Mine)

PRIOR SAFETY CONSIDERATIONS contd


Training Winding engine drivers Friction winch operators Messenger winch operators Clamp and lifting device operators Rope capping Tow vehicle, tractor driver

Initial rope-up procedureVery important, a combined effort amongst the OEM, EPCM and the Mine were put in to compile a detailed rope-up procedure. (Animated Procedure) This was reviewed many timesHazards were identified with in the procedure and a risk assessment was carried out to mitigate and control the risks.



Quality ControlSeveral inspections were conducted locally and internationally to ensure quality products. The rope-up equipment was inspected and factory tested by EPCM and the Owners team.

Rope Cutting Procedure Procedures were developed to ensure the ropes were cut accurately and safely. Platforms and life lines were installed in the shaft to safely access the ropes and attachments.



Friction RollersFriction rollers were incorporated on the friction winch as the main source of friction between the rope and the coiling sleeves of the friction winch.In addition the rope reelers were designed to pull through a brake generating a 2 ton rope pull (T2) as backup to the friction rollers if they had to fail preventing the rope from slipping



1700kN FRICTION WINCH & FRICTION ROLLERS

Friction Rollers


ROPE REELER BRAKES

CLIP


Below a list of items taken into consideration on site - Review of the rope-up procedure with all parties

involved, twice a day- Rope-up concurrently with other construction

work. Co-ordination of eight different contractors involved i.e. Work in head gear and in the shaft and plan to put the shift down

- Communication at all times, leaky feeder / two way radio, 6 channels

- Worked two shifts, handover and briefing sessions took place 06h00 to 07h00 and the again 18h00 to 19h00

3. SITE SAFETY CONSIDERATIONS


- Cleaning solvents, no diesel to be used to clean the head ropes (Slip could occur at reliance clamps and CLD)

- Barricading all the equipment to prevent unauthorised access

- PPE, grinding, cutting etc.

ON SITE SAFETY CONSIDERATIONS contd



- Daily task risk assessments- Heavy lifts - Load testing of cranes- Lifting and lowering of platforms- Tools with thongs used when working at heights and in

the shaft - Potential energy, tension in ropes and snatching areas - Moving equipment and machinery- Interface between the equipment i.e. either CLD or

Friction winch operational one at a time, not both.



- In order to prevent tension in ropes between the messengers winch and friction winch, the rope of the messenger winch was paid out and coiled in a figure eight before pulling with the friction winch

- Positioning and securing of equipment- Reeving of main rope, spotters with radios at critical

positions- Piloting of the bridles, conveyances and crossheads

through the shaft. The service winder was used in this instance



- In addition on each shift an engineer was legally appointed

- Supervisors were appointed for each task - All the equipment was tested to ensure proper control

and protection before the rope-up commenced- Emergency controls were put in place i.e. remote alarms

and stops



- Koepe winder free wheel through out the duration of the rope-up i.e. brakes hydraulically locked in the off position and motor torque disabled (Critical). Winder Brake off indication installed at friction winch driver.

- Working at heights, harnesses inspected and life lines installed and used

- Access control i.e. hard barricading & colour-coded hard hats

- At all times the T1/T2 tension in combination with the clamping and releasing of the ropes were taken in to account ensuring that no slip of the rope occurs



- 12 Hours shifts continuously for 13 days were worked. Fatigue of personnel were taken into consideration. Lunch packs, soft drinks, tea and coffee were provided. Portable toilets were positioned in close vicinity.

- Containers with tools and equipment were also positioned close to the activities.

- GOOD HOUSE KEEPING WAS OF THE ORDER FOR THE DURATION OF THE ROPE-UP


PPE: COLOR CODED HARD HATS


POSITIONING OF FRICTION WINCH (150 TON)


PREPARATION FOR SOCKETING AND FITTING OF ATTACHMENTS

Good housekeeping


ROPE REELERS BARRICADED


PROPER CONNECTIONS TO REEVE THE MAIN ROPE

CLIP


LIFTING HEAVY LOADS


CLEANING SOLVENTS (NO DIESEL ALLOWED)


CLOSING SHAFT AND INSTALL LIFE LINES


PROTECTION WHERE SNATCHING WAS DONE


TAIL ROPE CROSS HEAD AND LIFTING BEAM

Head Ropes

Tail Ropes


COMPRESSION BEAMS


MARKING, PREPARE AND ROPE CUTTING

ROUGH CUT

FINAL CUTTING MARK

MARKING

FINAL CUT


TAIL ROPE CLAMPING PLATFORMS INSTALLED

CLIP


HYDRAULIC JACKS TO BALANCE TENSION IN HEAD ROPES

PUMP

JACKS


MESSENGER WINCH CONTROL AND SAFETY


DEFLECTOR SHEAVE ROPE RETAINER


CRANES INSTALLED


CONVEYANCE INSTALLATION FLAT CAR


TESTING CLD AND FRICTION WINCH FULL LOAD


Koepe Rope Reelers

Friction Winch

Permanent Deflection Sheaves

Koepe Winder (free-wheeling)

Temporary Deflection SheavesCompression Beams & Deflection Sheaves

Messenger Winches

TESTING CLD AND FRICTION WINCH FULL LOAD

CLDs (1700kN Rope Pull)

CLD PULLING FORCE TEST1700 kN

FRICTION WINCHBRAKES ON


1700 kN FRICTION WINCH SUPPLY CABLES & EARTH


KEY LESSONS LEARNT

Being a project some activities fall behind and hence need to be accelerated or activities need to run concurrently not planned for in the schedule in order to meet deadlines. Additional planning is then required to ensure safe completion

A lot of patience and a good team spirit is required


CONCLUSION

The process followed, the rope-up equipment obtained, together with the dedication from top management and all parties involved the rope-up was completed safely with out any incident.

THANK YOU!QUESTIONS?

CLIP

Date post:	29-Sep-2015
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Impala Platinum 4 Rope Koepe Winder Rope-up (Patrick de La Hunt)

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