Professional Documents
Culture Documents
14
Koepe / Friction Hoists
H A R D
R O C K
M I N E R S
H A N D B O O K
A friction hoist with two skips in balance is normally suitable for hoisting from only one
loading pocket horizon and for a hoisting distance exceeding 600m (2,000 feet). Otherwise, a
counter-balanced friction hoist (conveyance and counterweight) is usually employed (for multilevel, shallow lifts, or cage hoisting). Source: Ingersoll-Rand
The practical operating depth limit for a friction hoist is 1,700m (5,600 feet) for balanced
hoisting and 2,000m (6,600 feet) for counterweight hoisting. Beyond these depths, rope life
may be an expensive problem. Source: Jack de la Vergne
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The hoisting ropes (head ropes) for a friction hoist are not required to be non-rotating for
depths of hoisting less than 800m (2,600 feet) provided right hand and left hand lays are
employed to cancel rope torque effect. Tail ropes must always be non-rotating construction
and connected with swivels at each end. Various sources
For a tower mounted skip hoist, the calculated static tension ratio (T1/T2) should not exceed
1:1.42, but 1:1.40 is preferable. For a ground mounted skip hoist, the calculated static tension
ratio should not exceed 1:1.44 but 1:1.42 is preferable. For a cage hoist installation, these
values may be exceeded for occasional heavy payloads of material or equipment transported at
reduced speed. Various Sources
Tread Pressure
Tread pressure should not exceed 17.5 kg/cm2 (250 psi) for stranded ropes and 28 kg/cm2 (400
psi) for locked coil ropes. Source: A.G. Gent
For lock coil hoist ropes, the tread pressure calculated for skip hoists should not exceed 2,400
kPa (350 psi), or 2,750 kPa (400 psi) for a cage hoist when considering occasional heavy
payloads of material or equipment. Source: Jack de la Vergne
For stranded hoist ropes, the tread pressure calculated for skip hoists should not exceed 1,700
kPa (250 psi) or 2,000kPa (275 psi) for a cage hoist when considering occasional heavy payloads
of material or equipment. Source: Largo Albert
Tail Ropes
The natural loop diameter of the tail ropes should be equal to or slightly smaller than the
compartment centres. Source: George Delorme
The total number of friction hoist wheel revolutions for one trip should be less than 100 for
skip hoists, but may be as high as 140 for cage hoists. Source: Wire Rope Industries and others
The hoist wheel rotation at full speed should not exceed 75 RPM for a geared drive, or 100RPM for a direct drive. Source: Ingersoll-Rand
Position
The distance between the hoist wheel and the highest position of the conveyance in the
headframe should not be less than 1.5% of the distance from the hoist wheel to the conveyance
at the lowest point of travel. Source: Largo Albert
At full speed, a time increment of at least a second should exist as any one section of rope
leaves the hoist wheel before experiencing the reverse bend at the deflector sheave. Source:
George Delorme
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Position (continued)
The clearance between the bottom of the conveyance, at the lowest normal stopping
destination in the shaft, and the top of the shaft bottom arrester (first obstruction) is usually 5
feet. This arrangement ensures that the weight of the descending conveyance is removed from
the hoist ropes. Source: Largo Albert
The tail rope loop dividers are generally placed below the arrester. The bottoms of the tail rope
loops are then positioned 10 to 15 feet below the dividers. Beneath this, a clearance of about
10 feet will allow for rope stretch, etc. Source: Largo Albert
Hoist Speed
Where the hoist line speed exceeds 15m/s (3,000 fpm), the static load range of the head ropes
should not be more than 11.5% of their combined rope breaking strength. The (ratio of) hoist
wheel diameter to rope (stranded or lock coil) diameter should not be less than 100:1, and the
deflection sheave diameter to rope diameter should not be less than 120:1. Source: E J
Wainright
The maximum desirable speed for a friction hoist is 18m/s (3,600 fpm). Source: Jack Morris
The maximum attainable speed for a friction hoist that can be safely obtained with todays
(1999) technology is 19m/s (3,800 fpm). Source: Gus Suchard
In North America, the desirable speed for cage service is approximately 2/3 of the optimum
speed calculated for a skip hoist for the same hoisting distance. Source: Jack de la Vergne
The hoist wheel diameter to rope (lock coil) diameter should not be less than 100:1 for ropes
up to 1-inch diameter, 110:1 for ropes to 1 inches diameter, and 120:1 for ropes to 2 inches
diameter. Source: Glen McGregor
A ratio of 100:1 (wheel diameter to lock coil rope diameter) is adequate for ropes of 25-35 mm
diameter. This should increase to 125:1 for ropes of 50-60 mm diameter. Source: Jack Morris
Rope tread liners on the hoist wheel should be grooved to a depth equal to one-third (1/3) of
the rope diameter when originally installed or replaced. The replacement (discard) criterion is
wear to the point that there is only 10 mm (3/8 inch) of tread material remaining, measured at
the root of the rope groove. Source: ASEA (now ABB)
On most fiction hoist installations, the maximum tolerable groove discrepancy is 0.004 inches,
as measured from collar to collar. Source: Largo Albert
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C H A P T E R 1 4
K O E P E / F R I C T I O N H O I S T S
Production Availability
A friction hoist is available for production for 108 hours per week. This assumes the hoist is
manned 24 hours per day, seven days per week, and that muck is available for hoisting. Source:
Jack Morris
With proper maintenance planning, a friction hoist should be available 126 hours per week (18
hours per day). Source: Largo Albert
Spacing
The minimum distance (design clearance) between a rope and bunton or divider is 5 to 6
inches. This is mainly because the hoist rope vibration is normally 2 to 3 inches off centre; 4
inches is considered excessive. Source: Humphrey Dean
The spacing between head ropes should be 1 inch for each foot diameter of the hoist wheel to
get an adequate boss for the deflection sheave. Source: Gerald Tiley
The easy way to design a friction hoist is to first determine the required hoisting speed and
payload then determine the ropes that are needed to meet the required SF. The hoist parameters
can then all be determined only considering the hoist ropes and line speed. Source: Tom Harvey
The distinguishing feature that should be recalled when designing or operating a friction hoist is
that weight is your friend. In other words, heavier ropes and suspended loads mean higher
force of friction and greater facility for braking, etc. Source: Richard McIvor
The rule of thumb (attributed to Wainright) that indicates a minimum SF of 7 for friction hoist
head ropes is not correct. There are a very large number of hoist installations worldwide that
have operated satisfactorily for many years at smaller SFs. In this respect, the regulations
stipulated for the Province of Ontario in Canada are a good guideline, anywhere. Source: Largo
Albert
To avoid stress concentrations, it is desirable to manufacture a friction hoist wheel in one piece.
Wheels up to about 3m (10 feet) in diameter can be shipped complete with shaft to most
locations. Source: Gerald Tiley
When designing a tower-mounted friction hoist, consideration should be given to the possible
avoidance of deflection sheaves, as they represent a maintenance headache. Source: Richard
McIvor
At full speed, a time increment of 0.6 second should exist as any one section of rope leaves the
hoist wheel before experiencing the reverse bend at the deflector sheave. This adds to the
headframe height, but the added clearance is desirable for maintenance and change-out of the
sheave wheels. Source: Largo Albert
While it is better to have the rope spacing the same at the hoist wheel and the head sheaves for a
ground mounted Koepe hoist, this is not necessary provided that the fleet angle of the outside
177
H A R D
R O C K
M I N E R S
H A N D B O O K
ropes is 10 or less. This is known because there are single rope friction hoists in Europe with
both head sheaves on the same headframe deck that operate satisfactorily, provided the fleet
angle is maintained at 60 minutes (10) or less. Source: Trfileurope
For a single rope ground mounted Koepe hoist, it is better to have the head sheaves in the same
plane as the hoist wheel. However, the head sheaves may be mounted on the same deck of the
headframe tower, provided the fleet angle of the outside ropes is not more than 1 to 2 degrees.
Source: Henry Broughton
While it is better to have the rope spacing the same at the hoist wheel and the skip attachment,
this is not necessary provided the fleet angle of the outside ropes is 10 or less when the
conveyance is at its upper end of travel. Source: Borje Fredricksson
The arresters (last resort) at the shaft bottom are designed to stop a full-speed conveyance at
2g, while an ascending conveyance must be stopped at less than 1g (i.e. 0.9g), although not
necessarily from full speed if it exceeds 15m/s (3,000 fpm). Various sources
The tail ropes should be oriented to overcome the Coriolis effect. If placed in the East-West
direction, the tail ropes will freely open and close. If the compartments are North and South,
the ropes will foul the separating spacers (loop dividers) if not widely spaced. Source: Gerald
Tiley
The Coriolis effect can be neglected, as it is much smaller than the movement at
acceleration/deceleration and due to rope torque of the tail ropes. Source: Borje Fredricksson
High-speed friction hoists [over 12m/s (2,400 fpm)] are oriented with the wheel diameter EastWest to minimize the effect of Coriolis acceleration on the tail ropes. Source: Jack Morris
The effect of Coriolis acceleration on the tail ropes is diminished when a fixed guide system is
employed, as opposed to using rope guides. Source: Jack de la Vergne
The tail rope weight is normally designed equal to the head ropes; however, tail ropes slightly
heavier than the head ropes will assist acceleration from the loading pocket. Slightly lighter tail
ropes will provide a greater SF for the head rope section above the conveyance as it approaches
the highest point of travel (the point at which uneven rope tension is most severe). Source:
Gerald Tiley
The distance between head ropes (spacing) varies between 8 inches and 12 inches. At 8 inches,
some installations experience rope slap but this is not considered a serious problem, since the
ropes are running at the same speed. (Author note: regular slapping is said by others to lead to
martensitic alteration, resulting in broken wires.) Narrow rope spacing may require that the rope
attachments at the conveyance be staggered. This can be accomplished by including a link at
every other attachment. Source: Humphrey Dean
The guideline for rope spacing is 8 inches up to 11/8-inch rope diameter, 10 inches to 1 inches,
12 inches to 1, 14 inches to 15/8, and 16 inches to 1. Drawhead connections can be
staggered but this is costly and complicates rope adjustment and maintenance. Source: Largo
Albert
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C H A P T E R 1 4
K O E P E / F R I C T I O N H O I S T S
Design and select two friction hoists at the same time. One is required for production hoisting and
the other for cage service.
Facts:
Solution:
Step 1:
Step 2:
Step 3:
A suitable cage hoisting speed will be about 2/3 V =10m/s (rounded up)
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H A R D
R O C K
M I N E R S
H A N D B O O K
Calculate the cage hoist cycle time (a cage and counterweight is assumed).
Step 4:
Step 5:
Step 6:
Try 6 lock coil ropes of 32 mm diameter weighing 5.58 kg/m and having a breaking
strength (BS) of 890 kN.
SF obtained
= 1.23
Maximum total suspended load = (35.5 + 26 + 20) + (35.5 + 33) = 150 tonnes
Skip Hoist
Try four of the same lock coil ropes 32 mm diameter, 5.58 kg/m, and BS 863 kN.
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C H A P T E R 1 4
K O E P E / F R I C T I O N H O I S T S
Maximum total suspended load = (23.7 + 16 + 17.6) + (23.7 + 17.6) = 98.6 tonnes
SF obtained
Step 7:
Cage hoist tread pressure = 150g x1,000/ (6 x 3.2 x 32) = 2394 kPa (9)
Skip hoist tread pressure = 98.6g x1,000/ (4 x 3.2 x 32) = 2360 kPa (9)
A wheel diameter of 3.2m should be satisfactory for both hoists. (On detailed
investigation, it may be increased to 3.5m to increase rope life).
Step 8:
Tail ropes can be custom manufactured to meet precise weight requirements (i.e.
kg/m).
For the cage hoist (assuming no deflection sheave), select three non-rotating ropes
weighing twice the head rope weight.
The head ropes weigh 5.58 kg/m; therefore, the tail ropes will weigh 11.16 kg/m with a 53
mm diameter. If the ropes are 34 by 7, the natural loop diameter will be 46 x 53 = 2,438
mm (unsatisfactory). If the ropes are 18 by 7, the natural loop diameter will be 60 x 53 =
3,180 mm (satisfactory).
181
H A R D
R O C K
M I N E R S
H A N D B O O K
For the skip hoist (assuming a deflection sheave is required to bring the conveyances
closer together in the shaft, say 2m between compartment centres), select three nonrotating ropes of weight = 4/3 x 5.58 = 7.44 kg/m with a 43 mm diameter. If they are 34
by 7, the natural loop diameter will be 46 x 43 = 1,978 mm (satisfactory).
Step 9:
The skip hoist RMS power = (24/6.3) x 4 x 5.58 x 141.25 = 2,300 kW (3,100HP)
The cage hoist RMS power = skip hoist factored for speed and out-of-balance loads =
2,300 x 10/16 x (10/14) 1.25 = 944 kW (1250) HP)
Facts:
Solution:
The hoist plant availability is shown in Table 14-1.
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C H A P T E R 1 4
K O E P E / F R I C T I O N H O I S T S
Skipping
Continued?
Frequency
Duration
(hours)
Factor
Equivalent
Hrs/Week
Shaft Inspection
LP inspection
Shaft bottom inspection
Manway inspection
Hoist from spill pocket
Hoist spill from spill ramp
Skip Hoisting
no
no
no
N/A
yes
yes
weekly
weekly
weekly
monthly
N/A
weekly
4
2
2
N/A
N/A
0.9
1.000
1.000
1.000
0.000
1.000
1.000
0.90
Lunch time
21st shift in the week
Change from ore to rock
Change back to ore
hoisting
Electrical/Mechanical
yes
no
no
no
daily
weekly
daily
(in above)
1.5
8
0.5
0.000
1.000
7.000
8.00
3.50
no
no
yes
no
shift
shift
shift
daily
0.1
21.000
(included above)
(included above)
1
7.000
no
daily
(included above)
no
no
no
no
no
no
yes
no
no
daily
after
shutdown
weekly
weekly
weekly
weekly
monthly
monthly
annually
no
no
no
no
no
Remarks
Work in Shaft
(included above)
0.1
2.000
4.00
2.00
2.00
Automatic hoist
2.10
7.00
0.20
1.00
0.20
1.00
4.00
no
1
1.000
0.2
1.000
1
1.000
4
1.000
Dress while hoisting
5
0.231
During Annual
Shutdown
quarterly
2
0.077
semi-annual
12
0.038
annually During Annual
Shutdown
annually During Annual
Shutdown
annually During Annual
Shutdown
500,000 tons
8
0.076
no
semi-annual
0.038
0.30
no
semi-annual
0.038
0.23
183
During inspection
No spill pocket
% spill
Automatic
1.16
0.15
0.46
0.61
H A R D
R O C K
M I N E R S
H A N D B O O K
no
semi-annual
Re-groove deflection
sheave or change liners
Annual maintenance
allowance for shaft signals
Headframe Annual
Inspection maintenance
Inspect & adjust deflection
sheave
Change-out head ropes
and adjust linkage
Change-out tail ropes
no
semi-annual
no
annually
no
no
no
no
no
During shaft
inspection
8
0.038
0.30
During Annual
Shutdown
annually During Annual
Shutdown
annually During Annual
Shutdown
36 months During Annual
Shutdown
48 months During Annual
Shutdown
annually During Annual
Shutdown
per week
1.000
2.00
per month
0.231
0.92
per week
per month
6
8
1.000
0.231
6.00
1.85
per week
per week
per month
4
2
4
1.000
1.000
0.231
4.00
2.00
0.92
per week
per month
per month
weekly
quarterly
weekly
0
4
3
0
8
4
1.000
0.231
0.231
1.000
0.077
1.000
0.00
0.92
0.69
0.00
0.62
4.00
63 hours
168 hours
105 hours
62.5%
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C H A P T E R 1 4
K O E P E / F R I C T I O N H O I S T S
14.6 Comparisons
Following is a comparison of ground versus tower mount friction hoists.
Ground Mount Friction Hoist
Listed below are ground mount friction hoist advantages.
Shorter headframe.
Steel headframe (concrete is preferred in tower mounts for rigidity reinforced concrete is not
subject to residual stresses).
Less susceptible to damage from overwinds, mine explosions, lightning, and earthquakes.
The longer rope between the hoist and the highest point of conveyance travel makes rope surge
and possible subsequent structural upset less likely.
Ability to operate without problems at a higher tension ratio (T1/T2). This is likely due to the
dampening effect obtained from the wide-angle wrap of hoist rope around the head sheaves and
the greater distance between the high point of travel for the conveyance and the hoist wheel.
Zero or one deflection sheave is required. Two are required for a ground mount one is subject
to reverse bending of the hoist ropes.
The hoist ropes are not subject to the elements icing is less of a concern.
The headframe shell can be used for shaft sinking simultaneous with Koepe hoist installation
above the sinking sheave deck.
185
H A R D
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M I N E R S
H A N D B O O K
Notes
186