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1 Health and Safety ExecutivePage 1 of 177 Safe manriding in minesSecond report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets Parts 2A and 2B This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in shafts and Unwalkable Outlets, originally produced by HM Inspectorate of MinesThe National CommitteeA National Committee for Safety of Manriding in Shafts and Unwalkable Outlets was formed and first met on 3 December 1973 and their first report was published in 1976. The Committee commenced work on their second report on 23 March 1976, the members being as follows:Chairman J D Blelloch Director of Engineering, National Coal BoardDeputy S Luxmore, HM Principal Electrical Inspector of Mines and Chairman Quarries, Health and Safety ExecutiveMembers T K Clanzy HM Principal Inspector of Mechanical Engineering in Mines and Quarries, Health and Safety Executive J B Hall Chief Mechanical Engineer, National Coal Board H M Harrison Mechanical/Electrical Inspector, National Union of Mineworkers R Hartill Chief Electrical Engineer, National Coal Board L C James Head of Technical Services, Mining Research and Development Establishment, National Coal Board E Loynes Representing the Association of Mining Electrical and Mechanical Engineers H D Munson Head, Engineering Group, Safety in Mines Research Establishment, Health and Safety Executive A Rushton Representing the British Association of Colliery Management A J Williams Chief Maintenance and Energy Engineer.

2 National Coal BoardSecretary G Scott HM District Inspector of Mines and Quarries, Health and Safety ExecutiveHealth and Safety ExecutiveSafe manriding in mines: Second report Page 2 of 177 This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of MinesLondon: Her Majesty s Stationery Office Crown copyright 1980 First published 1980 ISBN 0 11 883281 6 Health and Safety ExecutiveSafe manriding in mines: Second report Page 3 of 177 This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of MinesForewordIn publishing this second report the Committee has completed work on its terms of reference. A section on unwalkable outlets has not been included as many of the principles and recommendations for shafts are considered to apply.

3 The report is in two parts: Part 2A contains considerations, conclusions and recommendations on other items of winding equipment and installations not specifically referred to in the first report ; Part 2B contains supporting technical information and guidance on new Committee , having similar representation to the National Committee has been formed to review periodically experience on the application of the first and second Reports on Safe Manriding in Mines, and to make proposals, as appropriate. Information on the work of this Committee will be included in the HSE Annual Reports on Health and Safety in wish to thank the representatives of all the interested parties for their valuable help and co-operation in fulfilling the Committee s terms of reference. I have no doubt that these two reports will make a positive contribution to the Safety aspects of manriding in S MARSHALL HM Chief Inspector of Mines and Quarries Note: The Mines and Quarries Inspectorate is now part of the Health and Safety Executive, consequently Mines and Quarries forms referred to in the text will in future be issued by the Health and Safety Executive, Health and Safety ExecutiveSafe manriding in mines: Second report Page 4 of 177 This is a web-friendly version of Safe manriding in mines.

4 Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of MinesContents of report Part 2A 1 Introduction 72 Winding engines 8 General statement 8 The design guide 8 Guidelines for fabricated, cast and forged components 9 Bolted anchorages for winding engine brakes 10 Contamination of winding engine brake lining materials 10 Retention of electrical braking 11 Automatic application of dynamic braking on AC winding engines 11 Automatic application of electric braking on DC winding engines 12 Brake torque sensing 12 Automatic contrivances: electrical aspects 12 Supervisory devices for automatic contrivances 13 Conveyance position monitoring 13 Emergency brake solenoids 14 Control system Safety 15 Electric winding engine drums and drives 17 Steam winding engines and auxiliaries 19 Friction between rope and drum 19 Assessment of reliability of systems 20 Emergency winding apparatus 203 Headframe and shaft equipment 21 Design principles for arresstors in friction winding installations 21 Pit bottom buffers 23 Conveyance suspension gear 24 Conveyances for manriding 26 Winding ropes 27 Rope and rigid guides 28 Balance ropes 31 Control of balance rope loops 32 Monitoring of balance rope loops 32 Termination of wire ropes 33 Shaft side equipment 33 Shaft signalling systems 38 Headframe pulleys 40 4 Maintenance, testing and training 41 Statutory reporting 41 Planned activities related to mining environment 41 Maintenance procedures and documentation 41 Maintenance of foundations, buildings.

5 Structures and shaft linings 43 Maintenance of equipment in towers, headframes and sumps 43 Maintenance of ropes in winding installations 44 Lasers and other devices for aligning shaft equipment 45 Health and Safety ExecutiveSafe manriding in mines: Second report Page 5 of 177 This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of MinesProtection of steelwork from corrosion 45 Shaft air heating 45 Non-destructive testing of components of winding apparatus 46 Reassessment of non-destructive testing 46 Monitoring of mechanical equipment 49 Testing of friction winding engines 50 Brake performance test 50 Training for work in shafts 525 Other winding practices 53 Control systems: push button winding 536 Abstract of recommendations 547 Further work 58 Part 2B (including list of contents) 59 Health and Safety ExecutiveSafe manriding in mines: Second report Page 6 of 177 This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of MinesPART 2 APrinciples and recommendations for ShaftsHealth and Safety ExecutiveSafe manriding in mines: Second report Page 7 of 177 This is a web-friendly version of Safe manriding in mines.

6 Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of Mines1 Introduction2 The first report , Parts 1A and 1B, of Safe Manriding in Mines was published in one volume in 1976 following the Public Inquiry into the winding accident at Markham Colliery, Derbyshire, in 1973. A new philosophy of braking for winding engines is set out in the first report with recommendations for implementing that philosophy. Information is also provided, and recommendations are made, on headframe and shaft equipment, maintenance, testing and training, and other winding The first report was published as soon as possible so that guidance on improving standards of braking and associated equipment of winding engines could be provided in advance of more general considerations. Items then outstanding, including incomplete work and some new subjects, are scheduled in section 7 of Part 1A. The terms of reference given to the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets were moreover TO CONSIDER ALL Safety ASPECTS OF MANRIDING IN SHAFTS AND UNWALKABLE OUTLETS AND TO MAKE This second report is similarly published in Parts 2A and 2B in one volume, and generally follows the arrangement of Parts 1A and 1B.

7 It contains the necessary supplementary information and recommendations to comply substantially with the terms of reference. Furthermore, as a result of experience in implementation of recommendations in the first report , it has been felt necessary to make changes in respect of non-destructive testing; and these are referred to in the The sub- committees and working groups, formed by the National Committee for the production of the first report , were reconstituted to produce the second report and have now been disbanded. The National Committee recommends however that a Committee remains in being and meets periodically to review developments in manriding in shafts and the further work scheduled in section 7 of Part Safe manriding in unwalkable outlets has not been separately considered because many of the standards applicable to winding in shafts apply equally to winding in unwalkable outlets and major drifts. With regard to safe manriding in underground roadways, a Haulage and Transport National Steering Committee was formed in 1975 to make recommendations and produce a Safety Catalogue of information on Safety standards, practices and design of systems and equipment, with the object of reducing accidents resulting from transport and Safety ExecutiveSafe manriding in mines: Second report Page 8 of 177 This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of Mines2 Winding enginesGeneral statement6 Part 1A discusses the philosophy of winding engine braking with the objective that a mechanical brake should be capable of bringing a winding system safely to rest even in the event of failure of one component.

8 Bringing a winding system safely to rest is primarily defined as reducing the speed at least to that which can be accepted by pit bottom arresting devices. For these purposes, the emergency braking force is assumed to be reduced by not more than 50% and this is further discussed in paragraph Part 1A also discusses related matters including initiations of mechanical braking, but safe manriding in shafts is affected by failure or malfunction of all relevant components of winding engines: and this section extends the discussion to a wider range of such components including their operational design guide8 In Part 1A paragraphs 4, 13(5), 14 and 111(4) there is reference to a design guide for winding engine brake components. A description of the proposed content and an explanation of the Reserve Factor concept are in section 1 Part 1B. Since the publication of Part 1, a draft of the design guide prepared by the National Coal Board and SMRE* has been issued to the Health and Safety Executive and British suppliers of winding engines and brake gear An introduction in the guide sets out its aims, includes some fundamental design considerations, draws attention to the importance of fatigue and defines the Reserve Factor concept.

9 After the introduction the guide is divided into basic chapters, working chapters and background information chapters. The content of these is shown in the following lists:(1) Basic chapters Fatigue design Bending and dynamic factors for fatigue design Theoretical fatigue strength of a pin in a pin joint Fatigue of welded components Adjacent and superimposed stress concentrations Resolution of forces in a caliper brake Structural analysis moment distribution method (Hardy-Cross).(2) Working chapters Screwed rods Analysis of fatigue of shafts Design for welding Compression members Determination of stresses in brake shoes Analysis of stress in typical welded brake shoe Fatigue strength of a pin in a socket Bushes for linkages* Safety in Mines Research Establishment, Health and Safety and Safety ExecutiveSafe manriding in mines: Second report Page 9 of 177 This is a web-friendly version of Safe manriding in mines: Second report of the National Committee for Safety of Manriding in Shafts and Unwalkable Outlets, originally produced by HM Inspectorate of Mines(3) Background information chapters Examples of good and bad design for machined and welded components General requirements for mechanical brakes Recommended materials for mechanical brakes Stress concentration data Proformae for calculations.

10 10 Development of the guide is continuing on the basis of comments received and experience of utilisation; it is being refined, amended and, where appropriate, supplemented. Progress has already been made in establishing a common approach to the problem of design of mechanical brake components. Computer programmes which have been compiled will contribute to this and also ease the burden of calculation, including calculation of safe definitive life for components where necessary. Typical programmes are as follows: Resolution of forces in a caliper brake Analysis of stresses in screwed rods Determination of stresses in brake shoes Analysis of fatigue of brake shafts Analysis of fatigue of pins Design of compression members Design of actuating levers Design of brake actuating The guide is now at the stage where the first edition will shortly be available. Additional chapters giving information on brake holding down bolts and brake actuating springs have been The scope of the guide will be widened by the preparation of association monographs to cover stress analysis and material data for disc brakes, data for analysis of stresses in headframe pulleys and shafts, and data for analysis of stresses in drum shafts.