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    Hoisting Chapter PDF

    Uploaded by

    Victor Balboa

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    © All Rights Reserved
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    of 18
    802 UNDERGROUND MINE DEVELOPMENT see FIGURE 8.18. Continued 9.5.1 Components of Holst Plant ‘The hoist plant consists of all those components of the mine plant that are nocessary to elevate ore, coal, stone, or waste and to raise and lower personnel and materiel inthe mine. Ii made up of some of the constiuents ofthe mine plant that were discussed in Section 9.3. Classified by location, they consist of the Following: 1. Surface plant Hoist room (headtame- or ground-mounted) (1) Hoist drum or sheave (imparts motion to rope) @) Hise electrical and mechanical equipment (prime mover, brake, clutch, controls) ) Hoist copes (steel wice sirands, woven in a pattern or lay) », Headirame (Lower or A-frame, steel or reinforced concrete) (1) Idler sheaves (Q) Storage bins (ore and waste) ) Skip dump mechanism (overturning or bottom dusnp) 2 Shaft plant 8. Skips (bulk transport) b, Cages, elevators (personnel, materiel) . Shaft guides (tracks for skips and cages) SuerHoSsTNG SYSTEMS 903 3. Underground plant 2. Dump and storage bin . Crusher (if size reduction required for hoisting) ©. Loading pocket | 4. Personnel and materils-handling facilities Figure 9.19 assists us in visualizing these components o° the hoist plant, assuming a vertical shalt as the main access opening. With little modifies: | tion, the same layout would also sufie for an inclined shaft using hoisting (a | slope, ramp, of dhift mine difers, presumably because hoisting would not be used). ‘nel tof Biome 7 TD on re packet “y 5000 tons i : ae (4500 tonnes) ° 30m ran. Feeder Crher: skip inane sump FGURE 8:18. Components ofthe holt plant ntallad with x vertical she. (Aer Lucas ane ayeocs, 1973. By permission tom the Socety fo Mining. Metal, snd exploration, ay Liteon, CO) a 904 UNDERGAOUNO MINE DEVELOPMENT 25.2 Hoisting System It is with the hoisting system itseli—those components ot the hoist plant located in the hoist room—that engineering design is mairly needed. Three key factors govern hoist selection: 1, Production rate, of tonnage to be hoisted per unit of time 2. Depth of shaft 3. Number of levels to be accessed ‘There are only two hoist types commonly used today: drum and friction, A drum hoist stores the rope not extended in the shaft on the face of the drum. A {iietion hoist passes tho rope (or ropes) over the top of the drive wheel but does ‘ot store it. Figure 9.20 shows a general diagram of both types. In addition, a special drum hoist design for deeper shalts is occasionally required. The ra of mina hoes, (Top) Ooubl-cluched,double-um hoist. (Bet) Natiropetcion-sheava hoe. (Aor Russel, 1082. By permision rom Ye Sacaly fr Mining. etary, and Gigolo, ie, Lien, CO.) a wodiipienens at ——————— ‘mer woisTn svsteus 305 ‘multidrum Blair hoist was devised for doop mines in Scuth Attica, The configurations for vo Blair hoists are shown in Figures 9 2idand 9.2te. While there is no hard set of rules for selecting a type of hoist, Harmon (1973) and Russell (1982) have provided general applications (Table $2). In addition, Culp (2002) provides general guidelines. He makes note that technical criteria are often overshadowed by regional biases. Ths leads one country to prefer & fiction hoist for the same application where another world choose a drum hoist, Here is Culp’s summary of common hoist configurations and their most common applications 96.2.1 Single-Drum, Unbalanced Hoist. single-drwm hoist is the simplest type, with one rope and one conveyance (Fig. 9 21a) Because there is no balancing load, itrequites a very high ratio of power to capacity, It is the ‘moat exible configuration because there is no consideration required for the position of a balancing conveyance. The most common applications are shalt sinking hoists, auxiliary hoists (for escape and other low-uliization applica tions), and shallow service hoists, 9522 Single-Drum, Counterweighted Hoist. When configured with two rcpes, winding in opposite directions so that one conveyance ascends while the other descends, the conveyances balance each other and the power require: ‘ments decrease significantly (Fig. 9.216). This configuration is also known as ‘an “over/under” hoist, The balanced loads dectease power requirements ‘because one conveyance offsets the other so that power is reqaired only to lift ‘Teblo 9.2 Application of Hoisting Methods Drum Friction Sheave Multigrara Optimum depth, <6000 (8) < M00 (09) > 6000 (1.8) ‘em Maximum skip sapacity* tons (lonnes) 2805 8507) 56 (51) Maximum output ah (tonnes) 900 (#20) 2800 (2540) 1800 (1630), Pascutes Single rope Muicope Multirope Multilevel Single level Great dept Medium depth Limited depth Wide use in US. High production Best efficieney Wide use outside US. Stp capacity bad on MSHA prseltedfetor of ety aad mata ep on Sour: Harmon, 197; Resell, 1982, By peissan of the Soir for Minne, Meaorgy, and Exploration, ne, Litto, CO. ‘iaer Hower syerems 307 the payload and rope, but not the conveyance. The major disadvantage is that the rope lengths are fixed, requiring coordination between both conveyance poxitions. For example, if one conveyance is atthe tap in the dunping position, the other must be in the loading position at the bottom. Ali, as the rope stretches, especially when new, it must be adjusted in length to take out the stretch so that the conveyances simultaneously land at their correct position. ‘A common configuration uses one conveyance and a counterweight like a building elevator. Ths eliminates the need to precisely coordinste two convey- ance positions. On a single-drum hoist, two skips can counterbalance one another, but the configuration is practical for only one hoisting level, 9.52.3 Double-Drum Hoist. The disadvantages of single-drum over/ under hoist are eliminated with a double-drum configuration (Fig 921c). Here the ropes ate wound on separate drums sharing one drive shaft By setting the brakes on one drum and disengaging a clutch, the drums can be disconnected, AA single-clutch hoist will have one fixed drum and one winding drum, while a orbie-luich hoist can fix or wind either drum. This simplifies realigning the conveyances after rope stretch. Double-drum hoists are ideal fo: hoisting from multiple levels, 9.52.4 Bialr Multirope Hoists. While traditional érum hoisis can lift loads from very deep depths (> 10,000 feet or 3000 m), the limitation is that each conveyance is held by only one rope. As the hoisting distance increases, more of tne rope load capacity is used simply to hold of lilt the rope. As a result, at 10,00 feet (3000 m) of depth, very lite rope strength can be applied to lifting the payload. A Blair hoist solves this problem by looping a singe cope around 1 steave wheel at the conveyance attachment and bringing it back up the shaft thereby doubling the load capacity (Figs. 921d and 92le). There are many ways to attach the other end of the rope. It may be “blocked” or fixed in place at Lae top so that the hoisting speed is half the winding speed. ft may alsa be ‘wound on the second drum in the same direction as the other side so that they ‘both ascend or descend together. This increases the hoisting speed to the full dram speed and results in an unbalanced load, The load can te balanced by adding a sevond pair of drums linked either electrically or mechanically to the fist set (Fig 9.21 e). Blair hoists are not currently used in the United States, but ave applications elsewhere, particularly in South Africa, 9.62.5. Friction Hoists. Friction, or Koepe hoists male use ofthe fact that Toacs in balance often generate sufficient rope pressure on the sheave to be driven by friction. This allows multiple smaller ropes to share the load (Figs. 921f and 921g). Following the cules for rope diameter-to-dum diameter, smaller ropes decrease the size of the drum required, the required torque and power, and consequently, manufacturing costs. Additionslly, siace Iziction hoists are not subject to the squeezing forces of « deum hoist, the drum weight can be smaller. Friction hoist costs are typically 60% of the cast of a drum 308 unpenaroUNo INE OEVELOPMENT hoist for the same hoisting capacity. The number of ropes is usually four or six, but there are hoists with as few as one oF as many as ten ropes. ‘As a drum hoist begins to hoist a load from the bottoms of the shaft, the rope load is all on one side resulting in large starting torques, Because friction hoist conveyance positions are fixed relative to each other, tal rapes can be used to ‘counterbalance the rope loads throughout the hoisting cycle, Thus the loed balance remains constant throughout the shaft and starting torque is much lower. Friction hoists, therefore, require a smaller motor tc hoist the same load reducing both capital and operational costs ‘The disadvantages of friction hoists are that conveyance positions are Sxed relative to each other, similar to a balanced single-drum system, Therefore, they fare best used in either a conveyance and counterweight configuration for ‘multilevel mines or with dual conveyances for single-level mines, Secondly, the tension between the multiple ropes neods to be Kept nearly equal to reduce wear. As rope tension differences increase with the number of rapes employed, this reduces the practical hoisting depth to about 000 fet (1500 m). Lastly, the payload must not be more than U.3 times the weight of the ropes ‘and conveyance (on one side of the system) or the rope may slip on the winder, For example, if the rope, tail rope and empty conveyance on each side weighs 50,000 Ib, (22,700 kg) total, the payload is limited to 25,00 Ib. (11,350 kg). Another way of expressing this is thatthe tension in the rope(s) hoisting the load may not be more than 1.5 times the tension in the rope(s) supporting the empty conveyance. This means that in shafts shallower than about 750 feet (230 i), where there i less rope load, payloeds are limited. Dead weight ean be added to both sides to inerease the allowable payload, but st an increased cost 9.5.2.6 Performance Characteristics. With theit ciferent principles, shapes, and numbers and arrangements of ropes, the various hoisting systems exhibit quite diferent performance characteristics. In campating operating costs, the parameter that determines energy consumption, and hence cost, is the duty cyele of the boist. This is a plot of the instantaneous power fequirements versus hoisting time. In Figure 9.21, rope-veloity diagrams and duty eyetes forthe principal hoisting systems are shown, The main dilferenoes are associated with drum shape and the use or absence of» tail rope Usually the most attractive system for high-speed, high-production, low. ‘energy skip hoisting from a single level at moderate depths is the friction- sheave method. Using counterweights, it is also adaptable to. multilevel hoisting, and with ground mounting of the sheaves ean be used at depths to 000K (1.Skm) or more. Details of the installation of a fition-sheave hoist and its hoist room and headframe appear in Figure 9.22, 9.6 SPECIAL TOPIC: DESIGN OF HOISTING SYSTEM ‘The design process for a mine hoisting system should be understood by the mining engineer, even though the design and installation are contracted to an SPECIAL TOPIC: DESIGN OF HOISTING SYSTEM 309 FIGURE 9.22. Mulirop, cionshoave elsing syst, mounted n heackame, (Me Bur and Serneydorbug, 1082, By parison Irom ha Natona Ming Assotin, Washing, oy engineer-constructor firm and the equipment bid to a hoist manufacturer. ‘Typically, the mining company developing the mine assigns its own engineer= ing department to monitor the entire process, including both the planning and corstruction of the surface hoist plant. The design proces is examined in detail anc illustrated by the following example. The design procedure, equations, and discussion are taken in large part from Harmon (1973). Balanced hoisting. All mine hoisting systems are operated in balance to Feduce moments, torque, and power demand on the hoist. Generally, two conveyances (skips and/or cages) are suspended from one heist; sometimes, 31D UNOERGAOUND MINE DEVELOPMENT wten more than one level is to be serviced, a counterweight replaces one conveyance, It is designed with a weight equal to the dead load of the skip oF cage plus one-half the live load, To further balance the loads, a tail rope ean be installed; although rare with a drum hoist, itis normally used with 2 Ivition-sheave hoist to reduce slippage as well at moments. 2. Slippage in friction sheave hoisting. Slippage occurs in a friction-sheave hoist i the ratio of the rope tensions exceeds a theoretical limit (Figure 9.23) ‘The relationship is Bee en where T is rope tension, the subscripts 1 and 2 refer to the loated and emply skips, respectively, is the natural logarithmic base, 1 is coeficient of fricion = 045-030, and @ is angle of wrap from x radians (180°) for a headlirame-monnted haist to 1.3 radiaue (240°) for a ground-nounted lis In 2q, 9.1, the limiting ratio is 15-1. for # headlrame-mounted hoist and 18-19 for a ground-mounted hoist. To increase &, a deflection sheave ean be Used. To increase the sheave lining or rope lubricant can be varied 2. Wire rope size. Wire rope has a complex structure; several of the moze common types of hoist rope are shown in Figure 9.24, Basically, there are three sheave Ematy ap nA yt Less ‘ki ter sieate FIGURE 9.23. Anahsis of ftolon sheave hoist to determine whether rope slippage occur (Let Sround-mounted ols (Righ) Heatrame-mounted hoist 3 a ny of nd | i SPECIAL TOMIG- DESIGN OF HOSTING SYSTEM O1t Roundsuand ’ RounaSwand Flalenee rand FanenecSand Hosting Hove Holsing ore "Howing Rope’ etng Rope Locked Cot Nonotaing Tat FultLock HashLock Holsing Rope oF Balance Rope Shalt Guide Rope Shall Guce Rove FGURE 8.24, Construction of wir rope. Tha tee ype mest commonly aedin mine hlsing ‘30 round-strend, fatened sand, ad looked coy perssion from SIEMAG Nordberg Ficting Technology, Mizu, Wit) types used for mine hoisting: round-strand, flattened-strand, and locked-coil. 1 general, round-strand rope is used with drum hoists, attened-strand with friction-sheave hoists, and locked-coil for any system at depths over 32001 (096m), Tn designing a hoisting system, the two properties of wire rope that are most important are weight per unit length and breaking strength. These properties are given for the three popular hoist ropes in Table 93. Nove that properties for two qualities of ste] are included for round-strand and fattened-strand rape. ‘Tn selecting the proper sizeof wire rope for a hoisting application, the most critical consideration isthe factor of safety (Figure 9.25). Values in the United States are established by the Mine Safety and Health Adminstration (MSHA) and vary with the type of hoist, depth, and whether personnel are being Foisted; the stepped curve gives the minimum allowable values to hoist retsonnel. Standards set by the American National Standards Institute (ANSI) are the maximum load for personne! or materiel, Because ‘be weight of the rope must be taken into account in determining the total load on the hoist, the

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