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impala platinum 4 rope koepe winder rope koepe winder
IMPALA PLATINUM 4 ROPE KOEPE WINDER ROPE--UP SAFETY ROPE PREPARATION PATRICK DE LA HUNT We respect, care and deliver INTRODUCTION We respect, care and deliver 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. We respect, care and deliver PRESENTATION CONTENTS Presentation contents 1. 2. 3. 4. 5. 6. Back ground, winder and rope-up equipment details Upfront safety preparation On site safety considerations Photos Video clips Conclusion We respect, care and deliver IMPALA 16 SHAFT HEADGEAR LAYOUT On top, Cooling towers for the water cooled drives 7) Koepe Upper level 6) Koepe Lower level, brake hydraulics 5) Transformer level and Drives 4) Deflection sheave level 3) Service winder sheave Level 2) Tipping level 1) Conveyor level Bank Level Personnel Loading level (Sub Bank) We respect, care and deliver IMPALA 16 SHAFT KOEPE WINDERS ROPE-UP 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). We respect, care and deliver 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 We respect, care and deliver IMPALA 16#, 4 ROPE KOEPE WINDERS We respect, care and deliver DETAILS OF WINDING SYSTEM Winding Distance Motor Detail Drum Diameter Brakes Conveyance Mass Payload Rope Details – 4 Head Ropes and 4 Tail Ropes Rope Speed Man Winder Koepe Rock Winder Koepe 1601m 1640m 4300kW @ 57.3 rpm 4300kW @ 57.3 rpm 6.5m 6.5m 4 Channel Disc Brake, Escort Controlled 4 Channel Disc Brake Escort, Controlled Cage: 26,5 ton Skips: 26,5 ton CW: 42,25 ton 22.5 ton 25 ton Head Ropes: 54 mm Full Lock Head Ropes: 54 mm Full Lock Tail Ropes: 59mm Non-spin Tail Ropes: 59mm Non-spin 16 m/s 16 m/s We respect, care and deliver IMPALA 16 SHAFT CROSS SECTION South Skip 25t Skip 25t Cage 26.5t. Payload 22.5t East West Service Cage Counter Weight 42.25t Service Cage North We respect, care and deliver IMPALA 16 SHAFT KOEPE WINDERS ROPE-UP § 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: We respect, care and deliver FRICTION WINCH • A mobile 1700 kN Friction winch, designed to handle 6 ropes simultaneously. It will also be used on Impala 17 shaft We respect, care and deliver DEFLECTION SHEAVES AND COMPRESSION BEAMS We respect, care and deliver 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 We respect, care and deliver MESSENGER WINCHES AND DEFLECTOR SHEAVES We respect, care and deliver ROPE REELERS We respect, care and deliver RELIANCE CLAMPS AND ACCESSORIES We respect, care and deliver LAY OUT OF ROPE UP EQUIPMENT TO ROPE-UP SAFE!! Koepe Winder (free-wheeling) Koepe Rope Reelers Permanent Deflection Sheaves CLDs Friction Winch Temporary Deflection Sheaves Compression Beams & Deflection Sheaves Messenger Winches We respect, care and deliver 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) We respect, care and deliver PRIOR SAFETY CONSIDERATIONS contd § EPCM, Contractor selection and adjudication Very 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 Reviews Ensure 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 Assessment Combined Risk assessments through out the process was carried out to identify hazards (EPCM, OEM, Mine) We respect, care and deliver 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 procedure Very 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 times Hazards were identified with in the procedure and a risk assessment was carried out to mitigate and control the risks. We respect, care and deliver PRIOR SAFETY CONSIDERATIONS contd § Quality Control Several 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. We respect, care and deliver PRIOR SAFETY CONSIDERATIONS contd § Friction Rollers Friction 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 We respect, care and deliver 1700kN FRICTION WINCH & FRICTION ROLLERS Friction Rollers We respect, care and deliver ROPE REELER BRAKES CLIP We respect, care and deliver 3. SITE SAFETY CONSIDERATIONS § 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 We respect, care and deliver ON SITE SAFETY CONSIDERATIONS contd - - 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. We respect, care and deliver 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. We respect, care and deliver ON SITE SAFETY CONSIDERATIONS contd - - 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 We respect, care and deliver ON SITE SAFETY CONSIDERATIONS contd - 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 We respect, care and deliver ON SITE SAFETY CONSIDERATIONS contd - - 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 We respect, care and deliver ON SITE SAFETY CONSIDERATIONS contd - - 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 We respect, care and deliver PPE: COLOR CODED HARD HATS We respect, care and deliver POSITIONING OF FRICTION WINCH (150 TON) We respect, care and deliver PREPARATION FOR SOCKETING AND FITTING OF ATTACHMENTS Good housekeeping We respect, care and deliver ROPE REELERS BARRICADED We respect, care and deliver PROPER CONNECTIONS TO REEVE THE MAIN ROPE CLIP We respect, care and deliver LIFTING HEAVY LOADS We respect, care and deliver CLEANING SOLVENTS (NO DIESEL ALLOWED) We respect, care and deliver CLOSING SHAFT AND INSTALL LIFE LINES We respect, care and deliver PROTECTION WHERE SNATCHING WAS DONE We respect, care and deliver TAIL ROPE CROSS HEAD AND LIFTING BEAM Head Ropes Tail Ropes We respect, care and deliver COMPRESSION BEAMS We respect, care and deliver MARKING, PREPARE AND ROPE CUTTING MARKING FINAL CUT FINAL CUTTING MARK ROUGH CUT We respect, care and deliver TAIL ROPE CLAMPING PLATFORMS INSTALLED CLIP We respect, care and deliver HYDRAULIC JACKS TO BALANCE TENSION IN HEAD ROPES PUMP JACKS We respect, care and deliver MESSENGER WINCH CONTROL AND SAFETY We respect, care and deliver DEFLECTOR SHEAVE ROPE RETAINER We respect, care and deliver CRANES INSTALLED We respect, care and deliver CONVEYANCE INSTALLATION FLAT CAR We respect, care and deliver TESTING CLD AND FRICTION WINCH FULL LOAD We respect, care and deliver TESTING CLD AND FRICTION WINCH FULL LOAD Koepe Winder (free-wheeling) Koepe Rope Reelers Permanent Deflection Sheaves CLDs (1700kN Rope Pull) CLD PULLING FORCE TEST 1700 kN FRICTION WINCH BRAKES ON Friction Winch Temporary Deflection Sheaves Compression Beams & Deflection Sheaves Messenger Winches We respect, care and deliver 1700 kN FRICTION WINCH SUPPLY CABLES & EARTH We respect, care and deliver 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 We respect, care and deliver 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 We respect, care and deliver
