THE SAN XAVIER MINE:

HOIST COMMISSIONING

By
DANA IONET SPECHT

A Thesis Submitted to the Honors College

In Partial Fulfillment of the Bachelors of Science degree

With Honors in
Mining Engineering
THE UNTVERSITY OF ARIZONA
MAY 2OI1

Dr. Mary Poulton

DeparEnent of Mining and Geologrcal Engineering

STATEMENT BYAUTHOR

This thesis has bee4 submitted in partial fulfilknent of

requirements for a degree at The University of Arizona and is deposited
in the University Library to.be made available to boriowers under rules
of the Library.

Statement of Individual Work

Dana Specht: Mine Leader. San Xavier Mine Manger.
Responsible for coordinating the project with the mine.
Also responsible for coordinating and delegating team
duties at the San Xavier Mine.
Scott Shields: Contracting Leader. San Xavier Associate
Engineer. Responsible for coordinating with contractors
and setting up meetings.
Stephenie Mirka: Responsible for following project
requirements and insuring all research and team
deadlines were met.
Andrew Swazey: Responsible for technical data and
visual imaging.

April 6, 2011

San Xavier Hoist Commissioning

Team Seven:Team 7
Stephenie Mirka, Scott Shields, Dana
Specht, and Andrew Swazey

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MNE 498

Contents
Executive Summary......................................................................................................................... 1
Introduction .................................................................................................................................... 2
Scope of Work ................................................................................................................................. 3
Background ..................................................................................................................................... 4
Mine History ................................................................................................................................ 4
Hoist History ................................................................................................................................ 5
Current Hoist ........................................................................................................................... 5
Refurbished Hoist .................................................................................................................... 7
Usage ........................................................................................................................................... 8
Communication ........................................................................................................................... 9
San Xavier Hoisting Emergency Procedures .......................................................................... 10
RopeRanger Autonomous System .......................................................................................... 11
Rope .......................................................................................................................................... 11
Cameras ..................................................................................................................................... 12
Utilities ...................................................................................................................................... 13
Schedule ........................................................................................................................................ 13
Fall Schedule .......................................................................................................................... 14
Spring Schedule ..................................................................................................................... 14
Implementation Schedule ..................................................................................................... 15
Budget ........................................................................................................................................... 16
Hoist Upgrade Costs .................................................................................................................. 16
Commissioning Costs................................................................................................................. 17
Design............................................................................................................................................ 18
Risk Assessment ........................................................................................................................ 18
Opportunities and Challenges ................................................................................................... 20
Hoisting calculations ................................................................................................................. 22
Implementation......................................................................................................................... 23
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San Xavier Hoist Operating Hardware Manual ............................................................................. 23

Future Work .................................................................................................................................. 23
Conclusion ..................................................................................................................................... 24
References .................................................................................................................................... 27
Appendix A - San Xavier Mine Operating Procedures .................................................................. 28
Appendix B - Existing and Proposed Electrical Loads ................................................................... 30
Appendix C - Schedule and Budget ............................................................................................... 32
Appendix D - Risk Analysis ............................................................................................................ 35
Appendix E - Applicable MSHA Regulations ................................................................................. 37
Appendix F - Applicable OSHA Regulations .................................................................................. 44
Appendix G - Applicable Arizona Mining Regulations .................................................................. 46
Appendix H - Stantec Proposal ..................................................................................................... 47

iv

Executive Summary
The San Xavier Mining Laboratory (SX) outside of Tucson, Arizona, is a one-of-a-kind venue,
partly due to its working shaft. The SX has provided many mining engineering students with
vital experience before moving forward with their career. Capital has been raised to improve
the shafts hoisting system, and that capital will go towards the implementation of newly placed
hoisting equipment. This implementation will improve the functionality and safety of the hoist
system.
The project consists of three major parts: implementation and engineering verification of the
physical hoist system, implementation of automated hoist controls, and installation of a skip
viewing system. Besides the main project team, the project will include coordination with three
outside groups. The groups involved include Stantec Consulting Services for engineering
verification, SafeHoist representatives to assist with software implementation, and CCT &
Associates to assist with camera system installation. Implementation of the tangible pieces of
the project is to commence following administrative contract verification and signing. A budget
of approximately $15,900 has been estimated for the project. A general implementation
schedule was developed apart from the overarching project schedule to allow for any
unexpected administrative delays out of the project teams control.
At the time of this writing, the newly installed hoist is scheduled to be wound and attached to
the skip. This piece of the project was recently authorized and will be completed by the project
team.

Introduction
In any industry, safety should come first. The mining industry is no different. A lack of safety
will inhibit the amount of production that operating mines possess. Similarly, a research and
learning facility needs to operate in the same manner, in order to fulfill its purpose of
education. The SX, owned by the University of Arizona, utilizes the No. 6 shaft to train mining
engineering students in removing equipment, muck, and injured persons in the case of an
emergency. Although safe practices may be part of the culture within a mine site, hazards can
still exist. Undeniably, mine shafts and hoists are inherently dangerous if a malfunction were to
occur.
With the advancement of new technology, it is now possible to reduce the risks that hoisting
presents. The SafeHoist RopeRanger system can provide sensors and detectors to improve
the safety of working hoisting equipment. These sensors are installed on the hoist rope. The
detectors report the acceleration, oscillation, and tension of the rope. Additionally, this system
allows the operator to monitor any possible slack in the rope and ensures that the safety factor
remains constant. Shaft changes can be detected, as well.
Prior to installation of the SafeHoist system, a newly purchased hoist rope will be wound by a
team of undergraduate, design students at the San Xavier Mining Laboratory. This team has
developed a project management plan to refurbish the existing hoist by proposing safety
enhancements and automated hoisting controls. In addition to the installation of the
RopeRanger, a Lily Simplex Overspeed and Overwind hoist controller will be implemented.
Finally, the team has proposed that previously donated cameras be installed along the depth of
the shaft, in order to monitor the skip by a use of a BARCO multiple I/O port Central Processing
Unit (CPU).
These components of the proposed refurbishment require outside engineering professionals to
monitor the installation of said components, as well as ensure their reliability. The entirety of
this project will be performed with funds which have been allocated from the Universitys
Mining Engineering Department. Upon completion, the mines currently working shaft will
further accentuate the unique qualities of this underground, research facility. It will provide
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students and other visitors the opportunity to obtain knowledge about a mine shaft and hoist,
while working with improved safety conditions and advanced technological systems.

Scope of Work
The SX utilizes a shaft and hoisting system to both lower and raise mining and research equipment,
to remove earthen material from two lower levels, and to provide emergency rescue hoisting if
necessary. Currently, the operating system consists of a pneumatically driven drum and is manually
operated from an outdoor station.
The project team proposes safety enhancements and automated hoisting controls for the San Xavier
mine. The project will include hoist engineering calculations, system integration and component
compatibility investigations, and implementation of three systems:
1.) A donated SafeHoist RopeRanger autonomous system.
2.) An existing Lily Simplex Overspeed and Overwind Hoist Controller.
3.) Installation of a skip viewing system along the depth of the shaft.

Figure 1: San Xavier Hoist Commissioning

A newly purchased hoist rope would be wound as part of the refurbishment. Creation of an
operating manual and training procedure would also be within the scope of the proposed project.
The timeline for completion is two months, and will require approximately $15,900 in funding.
External sources of engineering and hoisting expertise are required to complete this project. All
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safety calculations will be reviewed by licensed engineers prior to making in-field modifications to
the existing system.
An electrical engineer will be required to confirm if the existing electrical system will be sufficient
and to ensure compatibility with the safe hoist system. A refurbished Lily Simplex Controller has
been installed at the mine; however, it has not been placed into service. A Safetronics field
representative will be required to integrate the SafeHoist system and to aid in the removal of the
current hoisting components upon commissioning of the system. A professional hoisting engineer
will be necessary to oversee the hoist rope winding and to approve all hoisting calculations
completed under the scope of the project.
Donated camera system components will be integrated with a BARCO multiple I/O port CPU and
screen to increase skip monitoring capabilities. Project team members will be required to install the
cameras and monitoring system. A CCT & Associates representative will be required for system
programming and camera integration with the CPU.
In order to decrease the workload of outside engineers and personnel, the project team will
calculate hoist engineering data, coordinate planned work, and complete installation of the various
hoist system components. The project team will also produce an operating manual and implement a
training plan for new hoist operators.

Background
Mine History
The San Xavier Mining Laboratory is a unique resource that allows students to gain leadership
and problem solving skills with hands-on experience running a fully operational, underground
mine. The University of Arizona Department of Mining and Geological Engineering has
operated the mine since 1958. In 1975, the University of Arizona assumed full ownership of the
zinc, lead, silver, and copper operation from Anamax Mining Company. The property is
comprised of over 90 acres, featuring a mine training and operations facility, a hoist house and
headframe, and work and lay down areas. Located approximately 23 miles south of Tucson,
Arizona, the mine is part of a closed network of mine workings surrounding the No. 6 Shaft.
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Figure 2: San Xavier Mine, 1978

The SX is currently the only mining laboratory in the United States with a working vertical shaft.
Three underground levels are currently operational, including an adit level and two working
levels at depths of 100 feet and 150 feet accessible from the shaft. Primarily a drill-blast-muck
operation, the mine is maintained by university students. This future workforce is heavily
involved in the operations of the SX as student leaders and volunteers spend weekly eight hour
shifts developing the mine and their skill-set. The facility is used for course work from many
different disciplines of education at the University of Arizona and also provides research
opportunities for educational, private, and commercial partners. For these reasons, the SX has
been recognized by the International Society of Mine Professionals for its dedication to
advancing safety and health in the mining industry.

Hoist History
Current Hoist
The hoist currently in use at the SX consists of a small, pneumatically powered, Gardner-Denver
air tugger and a 3/8 inch rope, as shown in Figure 2. At optimum conditions, the air tugger
maintains a 1.5 ton load capacity. This capacity has gradually been reduced due to infrequent
maintenance and constant exposure to the elements. Although normal production
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requirements do not exceed this capacity, the hoist is occasionally required to lift an Eimco 12B
tracked overshot mucker. The downward acceleration of the overshot mucker exceeds the
rated capacity by several hundred pounds and cannot be controlled by the brake alone. Thus,
lowering the overshot mucker requires the operator to simultaneously employ the break and
the upward hoisting controls to accommodate the weight.
In addition to the inadequacy of the air tugger, the 3/8 inch cable rope is not designed for
hoisting. When lowering the skip to the 150 foot level, the rope permits nearly 4 inches of
stretch, creating a hazard when miners below are on-loading ore carts or equipment. Many
time-consuming incidents have occurred in which ore carts have been tipped onto the skip,
spilling ore and requiring extensive energy to re-right.
Another cause for concern is the noise interference when operating the hoist. Located outside
in close proximity to the air compressor, the hoist operator is unable to hear directions. For this
reason, the hoist operator typically requires an assistant to listen to the bells and relay
directions. This often causes confusion and is potentially dangerous in emergency situations. All
factors considered, the current hoisting system is well below the MSHA required factor of
safety.

Figure 3: Existing Hoist

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Refurbished Hoist
The hoist to be commissioned at the SX was installed as a senior capstone project in 2008. The
hoist and original AC drive were donated from the Silver Valley Mining District of Idaho. A
comparable DC drive motor and 6:2 planetary gear reducer were donated by The National
Institute of Occupational Safety and Health (NIOSH). Additionally, US Gypsum provided the
electrical distribution consoles and the Program Language Controller (PLC). Prior to installation,
the 2008 senior team designed and poured a hoist foundation with a safety factor of 11. During
this time, the hoist components were remachined, while new drum bearings were installed, the
planetary gear reducer and the DC motor were attached to the hoist base, and an emergency
break operated by air pressure was mounted to the hoist. A SafeHoist system and a Lily
Simplex controller with location indicator were attached to the hoist and PLC for future
automation of the hoist. In addition to the hoist, a 5/8 inch, 18 strand cable rope was
purchased. It is important to note that MSHA requires all hoisting components to meet a
minimum safety factor of 7 for hoisting miners. Although the shaft is currently dedicated to
production, the system exceeds the requirements and would be capable of hoisting people in
the future.

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Figure 4: Refurbished Hoist

Usage
The hoist at the SX is dedicated purely to
materials handling. As students spend weekly
shifts at the mine drilling, blasting, and
mucking, they rely on an operator to hoist the
muck to the surface for dumping. Each level
maintains two ore carts, each weighing 1.6
tons when loaded. Other items commonly
hoisted include jack-leg drills, drill steels, rail,
booster fans, air and water lines, and

Figure 5: Student Mucking Underground

miscellaneous tools. Without the hoist and a

sufficient operator, advancement underground would not be possible at the mine.

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Communication
At the SX, a miners underground phone system and a bell system for signaling the hoist
operator are the only means of communications between underground personnel and hoisting
operator or engineers. Shaft bells are used as a method of communication between the hoist
engineer and personnel operating the cages and does not require use of the phone if
communications have been made clearly and with complete comprehension. The moving
location of the skip is unavailable and notification of delivery to desired location is made
through the use of the bell system.
Although this works very sufficiently, a need for improvement was recognized as latency occurs
during this communication and the resulting stop or go signal if altered by the attention of the
operator running the current air-tugger system. Adding to the latency of system operation, the
existing operating station is located away from and inside the hoist house. The essential
feature in any signaling system is that the signals be fully understood by both the engineer and
the bell ringer. Any person authorized to use shaft bells must realize that complete and
thorough cooperation is required between the bell ringer and the hoist engineer. If at any time
a signal is misunderstood or understood fully, the operator shall make contact via the phone
system prior to moving the skip. Mine operators must set the brake on the air tugger and walk
to the mine phone system to achieve communications currently. A secondary visual alarm
system has been added to the traditional bell system, because at times the ambient noise of
the air compressor and operating the air-tugger makes hearing the bell almost impossible. The
potential for missing either bell rings or light alarm signals exist while operating the system.
During these circumstances, it is imperative the operator of the hoist make contact with the
requesting bell ringer to ensure accurate and complete communications were made. After
receiving confirmation, the hoist operator could return to the air-tugger and make the
requested skip movements. Once fully commissioned, the mine phone will be located next to
the indoor operation station and will eliminate much of the time lag currently occurring.
Position location of the skip will be made available via a physical location depth gauge and level
indicator, and visual display through the RopeRanger hoisting graphical user interface (GUI).
Electric switches will be located at collar locations to identify skip location and to provide motor
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control commands. A touch screen display will provide location of the skip as well as numerous
other hoist monitoring functions.
San Xavier Hoisting Emergency Procedures
Currently, the only emergency hoisting procedure identified for an operator of the hoist or for
requesting mine operations personnel, is a 7-Bell emergency alarm signal. Upon the
identification of a hazard, potential hazard, or accident during hoisting operations, mine
personnel must ring the bell seven times in succession. The hoist operator should immediately
set the break on the air-tugger halting all further movement of the skip, proceed to the Mine
Phone System and ascertain further information. The existing air tugger system has a single
brake that can be applied while the newly refurbished system will have multiple brakes upon
completion of the installation.
In total, three braking systems are available for normal and emergency operations. A manual
hand assist brake, a fail-safe air/electric dual caliber brake, and the Lily Overspeed Controller.
The Lilly Overspeed Controller will serve as the operating braking system and is controlled via
the SafeHoist operating control panel or via an emergency stop push button. The manual
hand assist braking lever shall only be used in the event of complete failure to either the air
brake or the Lily Overspeed Controller. Its primary function is to be a parking brake and is to be
engaged when the skip is to remain at a set location for extended time periods. The newly
installed hoist now has a fail-safe air brake installed on the drum and will be the primary
braking component during an emergency. The primary brake is pneumatically and
electronically controlled. During the event of either a power loss to the motor, a loss of air in
the compressed lines, or from a general all stop called for by an operator during emergency
shut down scenarios, a dual caliber brake pad will cease movement of the drum. In the event
of over-travel, protection to the hoist and skip will be provided by an electric switch installed on
the head frame and at defined stations in the shaft.
Once the system is complete, all controls for the hoist operation including shaft location
dispatch will occur via the SafeHoist operator station controller. Until this work has been
completed, a manual operation mode is also available for use during hoisting events and can be
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engaged for raising and lowering of the skip. Controls for manual operation are located on the
controller station panel display. Braking during manual operation is achieved by the
engagement of the caliper brake pads via the all stop emergency button. Speed of the hoist
must be monitored closely by an authorized user and special attention must be paid to
eliminate overpowering of the brake. To perform manual movement operations, the SafeHoist
control panel, motor controller, and main power supply to the hoist must be energized.

RopeRanger Autonomous System

The RopeRanger hoist monitoring system is
a start of the art multi-sensor monitoring system
used to track critical operational and safety
components during mine hoisting. Monitoring is
obtained real time and can be displayed on a touch
screen operator SafeHoist display and control
station. The system is self contained and
environmentally protected against dust and

Figure 6: RopeRanger Monitoring Screen

contamination during use. It uses a 16 bit analog to digital converter while monitoring rope
tension, vibration, acceleration, speed, slack, overload and over-distance parameters. To ease
requirements for installation, the system utilizes wireless radios as to not interfere with existing
wire rope hardware and equipment. The RopeRanger system monitors tension sensitivity to
approximately 0.001% and is well suited for the 5/8 inch cable installed on the refurbished hoist
and drum assembly.

Rope
The 5/8 inch, 18 cable rope purchased by the San Xavier mine
must be wound by a licensed hoisting engineer. As shown in
Figure 7, the placement of the hoist drum was located to
maintain a rope fleet angle less than 1.5 degrees. The current
setup utilizes a 1.3 degree fleet angle to the sheave wheel.
This design factor is important in maintaining the integrity of

Figure 7: Fleet Angle

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the drum throughout its operating life. Angles exceeding 1.5 degrees can cause premature wear
and will not utilize the full length of the drum. This new rope has a capacity of 22.5 tons and a
safety factor of 8. All other design factors are shown in Table 1.

Table 1: Rope Specifications

Dead windings
Max fleet angle
Length
Minimum strength
Max diameter
Lays/drum width
Length/wrap
Layers
Max tension
Rope angle from horizontal

10
1.5
432.3
40868.1
5/8
38.4
5.9
1.5
5108.5
73.0

degrees
feet
Lb
in
ft
Lb
degrees

Cameras
A series of Intec wide angle cameras will be installed in the shaft for skip monitoring
capabilities. The cameras have multiple sealed injection cast alloy enclosures and use a Milspec connector to eliminate potential shorting caused in the event of water exposure in the
shaft. There are enough units to place one camera at the collar and a unit at each of the lower
level shaft stations at the 100 foot and 150 foot levels. The hoist operator will now have the
capability to adjust skip position to ensure an appropriate loading platform based upon
visibility. A BARCO multiple I/O port CPU and touch screen display will allow the operator of
the hoist to have multiple views simultaneously or to have a single isolated but larger screen
when necessary. Installation of the cameras will occur after the limit switches for hoist
operation have been installed. CCT & Associates are providing technical expertise for the
installation of the touch screen CPU and for potential integration with the hoist operator
monitoring station.

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Figure 8: Intec Wide Angle Camera and Features

Utilities
Power is supplied to the hoist house via an underground duct bank and terminated in panels
located in the hoist control room. As a result of previous investigations into the connected
versus demand load schedules of supplied power feed and utilization at the SX,
recommendations have been made to upgrade the system in total capacity. It is also
recommended that careful consideration be paid to live current demand when starting motors
at the SX, as a potential for overdraw may exist.
Currently, the mine is supplied with a 200A 3 Phase power feed source; however, it is rated for
400A according to Trico Power. In recent years this system was evaluated by other project
teams. A proposal for ideal power supply was made based upon the following calculations from
recommended electrical feed. An electrical engineer has determined the installation of the
electrical feed sources to the main control panels and PLC cabinets have been installed
correctly, however, verification of this conclusion could not be ascertained by this project team.
As a result, Stantec Engineering will provide an electrical engineer to perform a job site audit to
ensure there are no hazards to staff and personnel working in the hoist house and hoist control
room. The electrical engineer will also determine the demand versus connected load. These
determinations will ensure the existing power system is capable of handling the startup and
safe operation of the rebuilt hoist.

Schedule
The time table for this project has been an integral part of moving the project forward. While
scheduling setbacks have occurred, reporting and presentation deadlines have remained
unchanged. The project has progressed over an academic year, so the project time table was
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split into two semester schedules. Very little work was completed in the break between the
semesters, due to conflicting personal schedules. The semester time tables can be found in
Appendix A. While work on preparation for the physical implementation of the project has been
mentioned in the schedule, the time table of the physical implementation has been developed
to be independent of the academic schedule.
Fall Schedule
The fall work schedule was used for some parts of the project, but unexpected events caused
problems in completing some of the items on schedule. Additionally, some of the items on the
schedule were not completed due to changes in how the physical implementation would occur.
Changes to the schedule were driven by clarifications in the scope and changes in applicable
Stantec personnel. For administrative reasons, the scope changed from design and
implementation to designing an implementation plan to be executed when time permitted. This
change was due in part to Stantecs loss of Clyde Peppin, the former project mentor. The loss of
Mr. Peppin caused issues with coordination and communication with Stantec representatives,
delaying the implementation process. As a result of those unexpected events, no items
associated with system verification or physical implementation occurred in the fall. Despite
changes to the implementation and design items of the schedule, the project reports and
presentations were able to continue as planned. Initial project outlines and proposals were
completed on schedule, but were later revised as the project scope was clarified. Resource
requirements were defined, allowing for a budget to be created. The resource requirements
remained largely unchanged, but the budget was revised as the roles of the various groups
involved were redefined.
Spring Schedule
Changes in the fall schedule led to the need for revisions in the spring schedule.
Implementation of the project was moved to spring, pending full administrative approval for
the execution of the project. Dates for implementation are included in the spring schedule, but
have been delayed and are subject to further change pending complete final approval. Due to
the revised scope of the project, only one direct meeting with the new main project consultant,
Ed Thomas, was necessary. Ongoing telecommunication was used as necessary instead of direct
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meetings due to a revised and limited scope on the part of Stantec and the fact that Stantec
engineers are located in Phoenix, Arizona. Unlike the variability in timing available for
implementation, reports and presentation elements are to be completed on schedule.
Implementation Schedule
The implementation schedule has been developed to be separable from the academic schedule
due to administrative uncertainty and uncertainty with outside vendor representative
availability. Representative availability is a severely limiting factor in the implementation
process, so the implementation process has been divided into an order of events that must take
place to complete the project. This order of events is shown in Table 2. It is important to note
that the camera implementation process is separate from the hoist implementation process.
Table 2: Implementation Order
Description

Order

Groups Involved

Electrical review

Stantec

Hoisting calculations

Stantec, Design Team

Engineering review

Stantec

Hoist rope change out

Stantec, Design Team

Software implementation

SafeHoist, Design Team

Operating manual

Design Team

Placement design

Design Team

Wiring and installation

Design Team

System setup and software

CCT & Associates,

Hoist Implementation

documentation
Camera Implementation

implementation

Design Team

Having an implementation order instead of a dated schedule is of great benefit for this project.
Due to the small budget of the project when compared to large commercial mines and the fact
that time spent is an in-kind donation by a University partner, the outside company
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representatives will likely be working on this project only in their spare time. Work will likely
commence on weekends when the groups involved are available, meaning the implementation
will occur in fragments over an extended period of time.

Budget
Hoist Upgrade Costs
Prior to the completion of this hoist upgrade project, other hoist improvement projects have
commenced to that have lead to the final commissioning of the refurbished hoisting system.
Necessary previous projects have included construction of a hoist mounting base, rewiring the
hoist room to accommodate a large hoist motor, and refurbishing and installing the hoist used
in the proposed project. The cost for the rewire project is not included in the report for that
project, therefore the cost for that piece of the overall project is unknown. However, the costs
for the 2008 San Xavier Hoist Upgrade project are known. These costs should be considered
when considering the overall costs sunk into the overarching hoisting system upgrade. The
costs for the 2008 San Xavier Hoist Upgrade project are shown in Table 3.
Table 3 Project Costs
Item

Cost

Machine Work

$9,000

Epoxy

$120

Bolts

$140 (Shipping, Bolts donated)

Wire Rope

$1,200

Electrical

$800

Grease

$150

Gantry Crane

$700

Miscellaneous Equipment Rental

$400

Total

$12,510

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Commissioning Costs
Project cost is an important piece in overall project management progression, so a cost
schedule has been developed for the hoist upgrade. This cost schedule has been developed on
an all-inclusive basis, taking into account all known major costs from initiation to completion of
the hoist upgrade process.
The project includes coordinating with three major outside sources and winding the hoist rope.
Outside sources consulted in this project include Stantec Consulting Services, who provide
engineering consulting services, SafeHoist, the manufacturers of the hoist controller system,
and CCT & Associates, a solutions consulting group familiar with the camera functionality and
construction. A generalized breakdown of the project costs is listed in Table 4. A full breakdown
of the associated costs can be found in Appendix A.
Table 4 General Costs
Description

Cost

Stantec
Project Management, Controls

$1,353

Site Visit

$4,364

Historical Document Review

$1,361

Electrical Design Review

$1,913

UA Report Review

$308

Miscellaneous Fees

$3,901

SafeHoist
Site Visit

$700

CCT & Associates

Site Visit

$1,000

Equipment
Rope Attachments

$500

Camera Installation Equipment

$500

Total

$15,900

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The majority of the costs are associated with consultation with the outside sources, but there
are some equipment costs as well. Costs associated with Stantec are primarily for engineering
services to oversee hoist implementation and verify calculations associated with the hoist
system. The costs associated with SafeHoist are for a company representative to visit the hoist
and assist with the SafeHoist RopeRanger system setup and implementation. Similarly,
representatives of CCT & Associates will need to visit the SX as well to assist in the setup and
installation of the camera system and potential integration with SafeHoist operating systems.
Cost estimates for the CCT and SafeHoist representatives are for flights and hotels only; time
spent working on the project by these representatives will be an in-kind donation. Additional
costs will be associated with winding the hoist rope and the camera installation. The hoist rope
equipment and camera equipment costs have been roughly estimated, but are unlikely to
exceed the costs listed. Costs for winding the rope include the purchase of cable clamps,
thimble, clevis, and safety latch devices.
Considering all the elements of the implementation plan, the estimated cost to complete the
project is $15,900. Financing for the project will be from the University of Arizona Mining
Department budget as funded by the Science Foundation Arizona program. This cost estimate is
lower than the actual value, due to in-kind and other donations by the outside sources
involved. SafeHoist and CCT & Associates are giving in-kind donations by sending
representatives to assist with their respective systems. Services provided by Stantec will not be
donated, but Stantecs cost estimate does include a fifteen percent preferred customer
discount.

Design
Risk Assessment
Prior to project initialization, a Job Safety Analysis was performed on February 12, 2011 to
ensure the teams awareness of all safety hazards present at the San Xavier Mine. This item is
included in the appendix for further reference.

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During the completion of this analysis, both behavioral and hazard checks were made. An
examination of the required documentation and Lock Out/Tag Out/Try Out (LOTOTO)
procedure was completed during this analysis. Also, emergency equipment, such as fire
extinguisher and eyewash station, was located. Several factors were incorporated into the
behavioral analysis. These include positioning all personnel away from moving objects,
ensuring visibility in the area, establishing that no lifting will be required, and making certain
that communication during the project will be properly coordinated. An overview of Personal
Protective Equipment (PPE) that must be worn while in the mining laboratory was discussed.
On the other hand, a hazard check was comprised of identifying other concurrent jobs on-site,
weather issues, and proper lifting equipment, as well as a number of other hazard inspections.
Additionally, a hoist risk analysis was performed in order to assess any risks that could affect
personnel involved in the project. Hazards within the project can affect the maintenance,
construction, and operation of the equipment.
Both mechanical and electrical problems can disrupt the maintenance of the hoisting system.
Many critical tasks exist for reducing these risks. For example, the hoist, sheaves, and rope all
possess the potential for the following mechanical problems. In order to minimize any
potential risks, suspended loads, sources of energy, rotating equipment, and pinch points need
to be identified. Also, other dangers may arise mechanically, in the form of slips, trips, falls,
falls from a height, noise exposure, chemical exposure, falling objects, lack of ventilation,
moving equipment, and flammable substances. In addition to the previously listed risks,
conveyances from the haulage level also includes the possibility of falls from a height in the
shaft, falling rocks in the excavation, and falling items in the shaft. In order to minimize the last
hazard, fall protection should be in place above and below the station.
Electrical maintenance problems may arise through the main power, main drive, control power
and voltage, safety interlocks, and compensation sheaves. Issues with the main power can be
identified as originating from any sources of energy, suspended loads, pinch points, slips, trips,
and falls, falling objects, and falls from heights, as well as noise and chemical exposure.

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Flammable substances, moving equipment, lack of communication, lack of ventilation, security,

and arch flashes are also included in these possible sources of danger.
Hoisting hazards can also impact the construction during the project. Mechanical and electrical
risks include suspended and moving heavy or large loads, sources of energy, rotating
equipment, pinch points, slips, trips, and falls, and falls from heights. In addition, any chemical
exposure, noise exposure, flammable substances, lack of ventilation, falling objects, and mobile
equipment may pose a problem. Finally, workers lacking task-specific skills can affect the
construction that will take place on the hoisting system. Civil hazards consist of the prior issues,
as well as any excavation blasting in the foundation.
Finally, this project may impact the operation of the system. In order to mitigate any hazards
that will affect the operation of the hoist, several resources can be provided on site. Adequate
emergency planning, proper guards on moving equipment, as well as sufficient transportation
for personnel, material, and equipment can minimize any hazards. Also, environmental risks
and ergonomics must be taken into consideration. The design team should ensure that proper
access is available for all equipment and personnel in the working areas.

Opportunities and Challenges

This project has required a solid project management plan to ensure timelines are met and the
project reaches completion by May 2011. It commenced with the knowledge that several risks
would be present. These risks have evolved into challenges over the course of the project
timeline.
Primarily, an unexpected setback occurred during the latter part of January. The project teams
original mentor, Clyde Peppin, left Stantec to pursue opportunities elsewhere. As a result,
Edward Thomas (also from Stantec) became the new Project Manager. Mr. Thomas knowledge
of the hoisting upgrade project was limited at the time. This required him to take time to read
the teams project proposal, as well as find time to travel out to the project site.
In addition, a risk to the completion date has been identified as consultant availability and
engineering support. While the project has an established budget, much of the effort devoted
20 | P a g e

to this project comes in the form of donated time and services. All three previously mentioned
external resource requirements have been or are donating time to the project with an
understood agreement of availability to perform. For example, Mr. Thomas is involved in other
various projects for Stantec, which has required him to fit the UA project into his schedule.
Since his office is located in Phoenix, Arizona, it was difficult for him to find time to travel down
to make a preliminary site visit to the San Xavier Mine. This conflict with time resulted in a
delay in Stantec drafting a project proposal for Mr. Ros Hill, the Director of San Xavier Mining,
to approve. This delay in Stantecs work has consequently postponed SafeHoists visit to the
San Xavier Mine. SafeHoist is unable to install their equipment until the rope is wound on the
hoist drum.
Additionally, time commitment for student team members has proved to be a challenge. Since
all four members are enrolled in their final year of their undergraduate career, it has been
difficult to fit meetings into their schedules. The members have commitments with work and
school, and two hold leadership positions at the San Xavier Mine. These demanding schedules
have created difficulties in the organization of team meetings and site visits. Also, as of
December 2010, the academic schedules of the team changed, in accordance with the
Universitys policies. This created further problems when attempting to find agreement among
their schedules. In order to complete the required work by the project deadline, a project
management plan was developed by the team of students. This plan has allowed for some
deviation to the proposed schedule.
During the engineering analysis of existing and proposed hardware, details for compatibility
and capacity will either show compliance or the need for further infrastructure development.
Due to the postponement of many of the projects phases, it has been determined that the
project management plan will be passed on to other students in May 2011, in order that the
project can be completed in the fall semester of 2011.
Just as there are risks that may cause delays, there are also opportunities to expedite the
project in the future. With the involvement of vendors that are engineering professionals as
well as product suppliers, projections for time commitments and for necessary resource
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involvement may become reduced. Stantec engineers are well versed in safe hoisting
techniques and will recognize potential pitfalls, unidentified by the student team. SafeHoist
professionals have installed similar systems globally and could sufficiently reduce the time
requirements for installation. Experts may also recommend colleagues from their past
experiences to assist with the San Xavier Hoist Upgrade Project. One of the positive outcomes
from our change in mentor is that Mr. Thomas is a University of Arizona graduate. As a student
working at the San Xavier Mine, he helped construct the headframe. This has proved to be an
asset, as far as knowledge and time is concerned, since Mr. Thomas is aware of the background
of the mining laboratory.
Another opportunity for success came in the form of donations to the Mining and Geological
Engineering Department. Time, effort, and equipment have already been donated to the San
Xavier mine to enhance the hands-on learning environment. Additional hardware and time
commitments donated to the mine could decrease the amount of external and internal
resources required for successful project completion.

Hoisting calculations
The San Xavier Mine has attempted to upgrade its hoisting system since 1978 when the current
headframe was erected. Since then, multiple hoisting calculations have been conducted to find
an optimum solution in ore handling. The unique situation encountered in 2008 was the
inability to choose the perfect hoist, but instead to optimize the hoist donated to the mine.
Using all calculations with current knowledge enabled the team to accurately confirm or
recalculate the necessary information pertaining to this hoist. Pertinent information regarding
the hoist can be found in Table 5. All correct calculations performed within the last ten years
are available in Appendix G. Through the research and calculations performed by this team, all
components of the hoisting system exceed the minimum factor of safety of 7 set forth by
MSHA.
Table 5 Hoist Specifications
Hoist Type
Hoist Drum

Single Drum
22.5

in. Diameter
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Hoist Gear
Drum Width
Drive Gear
Dist to sheave H
Dist to sheave V
Lifting on Hoist
Drum RPM

48.0
24
4.0
46.5
40.1
4885.4
17.0

in. Diameter
In.
in. Diameter
Ft.
Ft.
Lb.
rpm

Implementation
Once all contracts have been signed and authorization from the University of Arizona
Contracting Services has been given, actual physical implementation of the hoist improvement
project will occur. Primarily, a safety audit and electrical review will be conducted by a small
group of engineers from Stantec. Upon completion of these mandatory items, they will
supervise the student project team in winding the newly purchased rope on the hoist drum,
safely and securely. Subsequently, Mr. Mike Beus from SafeHoist Inc. will install the
RopeRanger and Lily Simplex Controller systems. He will also aid in the removal of the current
hoisting components. Ultimately, volunteers at the student mine will install the cameras along
the shaft, as well as the monitoring system. A representative from CCT & Associates will be
required in order to program the system and integrate the cameras with the CPU.

San Xavier Hoist Operating Hardware Manual

Accompanying this report is an operating manual for the combined components of the
SafeHoist and RopeRanger operating systems. This manual is tailored specifically for the San
Xavier Hoist and will serve as a training guide outlining the safe operating procedures.

Future Work
This project advances the functionality of the hoist greatly, but further work could improve the
functionality of the hoist. These improvements are beyond the scope of this project, but further
projects could bring the hoist systems abilities forward.

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One goal for the hoist system is to become man-rated. Man-rating the hoist would involve two
major projects, re-lining the shaft with non-flammable materials, and changing out the skip for
a man-rated cage. The existing cribbing and guide rails for the skip are all wooden, but law
dictates that shaft lining and guide rails in a man shaft are non-flammable. Another project that
would be required before man-rating is installation of a man cage. The current skip does not
have a surrounding cage, and is not man-rated. To prepare the hoist system for man-rating,
future work would include re-lining the shaft with steel cribbing and installing a steel man cage.
Another goal for the hoist system is to eventually service the entire shaft. Due to problems on
the 250 foot level, the serviced shaft stations only include the 100 foot and 150 foot levels. This
project allows the hoist to reach the 250 level, but the condition of that level is not fully
understood. In order to reach the 250 level, inspection and rehabilitation of the shaft between
the 150 and 250 levels would be required. Additionally, the shaft station would need to be
rehabilitated and have communications extended to that level.
As far as this shaft is concerned, the future projects listed would essentially complete the
functionality of the hoist. The future work mentioned would allow the hoist to carry any normal
load, human or otherwise, and hoist along the entire length of the shaft. Absent sinking the
shaft further or any other type of earthwork, the shaft would be advanced to its maximum
functionality.

Conclusion
The San Xavier Hoist Improvement project, proposed by Team Seven Stephenie Mirka, Scott
Shields, Dana Specht, and Andrew Swazey, was a tremendous learning experience. The project
quickly evolved from what we initially perceived to be an engineering design assignment to
what was really a project management learning experience. Throughout the two semester
terms, our mentors Mr. John Fenn and Mr. David Naccarati continually reminded us our
ultimate goal is to manage our work such that if an immediate need to pass on responsibilities
for completion of the project occurred, another qualified team could resume work and
successfully finish the job.

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A major change to our project was the deviation from an engineering design to commissioning.
Initial perspectives of the work was that our team would be required to investigate current
hoisting conditions, calculate hoist and load parameters, and implement changes as required.
Although this is true in respects, we quickly realized much forethought and work to accomplish
these goals had already culminated.
Much of the time we spent developing this project was investigating what had been done
before we assumed responsibility for completing the hoist improvements. Other work crews in
years passed had culminated their design projects by completing not only technical reports, but
also providing a product. Unfortunately, the data and the respective final reports were not
stored in locations available to our team. Many hours were spent tracking down data from the
past 30 years that are essential for the completion of our specific goals. Not only would our
investigations require tracking down this information on site at the SX Laboratory and the
University of Arizona Mining and Geological Engineering Department, our search spanned to
Idaho, Nevada, Montana, California, and Washington. The resulting finds of material were
astounding in that Team Seven realized our project was beginning a transition from design to
commission.
A major challenge to this project has been the continual timeline setbacks as a result of
commitment and coordination with consulting engineers. Although design work for the hoist
change-out had already been completed by students, this information had to be transferred to
professionals and reviewed for safety. The cause for delay throughout the past seven months
has been a unique series of events including a change in mentor, waiting time for the right
person to be available when needed, and the extended wait while project proposals are
reviewed, revised, and ultimately approved. Once completed, the potential contract then had
to be processed through the University of Arizona Contracting Services group. At this time we
are still waiting for a signed contract to be delivered so that the design work can be completed
safely and efficiently. In addition, commitments to perform much of the outside consulting
work under in-kind donations places our priority below money making jobs. As an industry
partner and a friend to the University, these companies are doing as much as possible to help.
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26 | P a g e

References
Birbeck, Scott, Philip Requadt, and Erron Winsor. SX Hoist Upgrade: Replacing the Hoist at the
San Xavier Student Mine and Research Laboratory. Rep. 2008. Print.
Brokenshire, Peter, and Susan Andersen, eds. Hoist and Haul 2010 Proceedings of the
International Conference on Hoisting and Hauling. Littleton: Society for Mining
Metallurgy, 2010. Print.
Code of Federal Regulations, Mineral Resources, National Archives and Records Administration
30 (1997). Print.
"Crosby Clips: Warnings and Application Instructions for Wire Ropes." 2008. The Crosby Group,
Inc.
Featherston, John, Steven Bastian, and Tim George. The San Xavier Re-Wire Project. Rep. 2006.
Print.
Featherston, John. The San Xavier Re-Wire Project. Rep. 2005. Print.
Hartman, Howard L., ed. SME Mining Engineering Handbook. 2nd ed. Vol. 2. Littleton: Society
for Mining, Metallurgy, and Exploration, 1992. Print.
Peppin, Clyde. "Hoist Risk Review Notes." 1 Oct. 2010. E-mail.
Phelps Dodge Corporation, Copper Queen Branch, Mechanical Department. Code of Safe
Practice for Hoist Engineers (1969). Print.
San Xavier Mining Laboratory. SX Safety Manual. The University of Arizona.
Walker, Jr., W. Dan, and R. W. Stahl. "Recommended Procedures for Mine Hoist and Shaft
Installation, Inspection, and Maintenance." Bureau of Mines Information Circular 8031
(1961). Print.

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Appendix A - San Xavier Mine Operating Procedures

Safe Hoist Operating Procedures
1. Only authorized persons shall be in hoist rooms or hoist cabs.
2. Personnel shall not ride loaded skip decks, cage decks, or buckets with muck, supplies,
materials, or tools other than small hand tools.
3. When a manually operated hoist is used, a qualified hoist operator shall remain within
hearing of the telephone or signal device at all times while any person dependent on
that hoist is in the mine.
4. Only experienced hoist operators shall operate a hoist except in case of emergency and
when new operators are being trained.
5. When personnel are hoisted in buckets, rope speed shall not exceed 500 ft/min and
shall not exceed 200 ft/min when approaching the intended station or stopping point.
***Note: The hoistman shall respond to call signals for a cage, before presenting the cage to a
person on a level. Until the hoistman has responded to a signal, thereby acknowledging the
receipt of that signal, no person will attempt to signal on the shaft bell system, nor shall any
person attempt to load a cage until the hoistman has acknowledged the receipt on the
squawker.

Hoist Bell Signals - Hoist Operators Guide

Cage Position Adjustment Signals:
Slow Bells Mean Move Cage Slowly
1 Bell - Stop Immediately
2 Bells - Lower Cage
3 Bells - Raise Cage
General Communication Signals:
5 Bells - Turn Air On/Off
7 Bells - Go to Mine Phone Immediately - Possible Emergency
Surface Cage Dispatching Signals:
1 Long Bell + 1 Bell + 1 Bell - Send Cage to Shaft Collar
1 Long Bell + 1 Bell + 2 Bells - Send Cage to 100 Level
1 Long Bell + 1 Bell + 3 Bells - Send Cage to 150 Level
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1 Long Bell + 1 Bell + 4 Bells - Cage Released from Collar

100 Level Cage Dispatching Signals:
1 Long Bell + 2 Bells + 1 Bell - Send Cage to Shaft Collar
1 Long Bell + 2 Bells + 2 Bells - Send Cage to 100 Level
1 Long Bell + 2 Bells + 3 Bells - Send Cage to 150 Level
1 Long Bell + 2 Bells + 4 Bells - Cage Released from 100 Level
150 Level Cage Dispatching Signals:
1 Long Bell + 3 Bells + 1 Bell - Send Cage to Shaft Collar
1 Long Bell + 3 Bells + 2 Bells - Send Cage to 100 Level
1 Long Bell + 3 Bells + 3 Bells - Send Cage to 150 Level
1 Long Bell + 3 Bells + 4 Bells - Cage Released from 150 Level
***Note: Hoist Operator will not move cage unless all bell signals are understood and a signal
has been received from both the sending and receiving shaft stations.

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Appendix B - Existing and Proposed Electrical Loads

Existing Electrical Capacities:
Entire Property

480V, 3, 200A

Hoist House

480V, 3, 100A

Surface Substation

480V, 3, 100A

Existing Electrical Loads:

Hoist House
Operation

Volts (V)

Phase ()

Full Load Amperage (A)

Welder

480

Rated 50A

Grinder

110/120

15

Drill Press

110/120

15

Band Saw

110/120

Cap Lamp Chargers

220/240

30

General Receptacles

110/120

General Lighting

110/120

Rated 15A

Underground Circuit

110/120

Rated 20A

Security Light

110/120

15

Radio

110/120

Rated 60A (20A X 3 circuits)

(Bells, Lighting, Outlets)

Total Full Load Amps

131

Surface Substation
Operation

Volts (V)

Phase ()

100' & 150' Ventilation

480

Full Load Amperage (A)

15

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Adit Level Ventilation

480

15

100' Level 3 Electrical

480

15

Adit Level Electrical

480

15

Total Full Load Amps

60

Existing Total Full Load Amps (Entire Property)

191

Proposed Electrical (Rating) Amperages:

Operation

Volts (V)

Phase ()

Change Room / Office

480

200

Electric Compressor

480

125

Decline Ventilation Fan

480

125

Adit Level

480

60

100' Level

480

60

150' Level

480

60

Hoisting System

480

125

Total Proposed (Rating) Amperage

Full Load Amperage (A)

755
453

(Figure on 60% of full load at any given time)

Total Needed Electrical Capacity

567.6

600A

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Appendix C - Schedule and Budget

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Appendix D - Risk Analysis

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36 | P a g e

Appendix E - Applicable MSHA Regulations

30 CFR 57.16011 - Riding hoisted loads or on the hoist hook.
Persons shall not ride on loads being moved by cranes or derricks, nor shall they ride the
hoisting hooks unless such method eliminates a greater hazard.
30 CFR 57.16017 - Hoisting heavy equipment or material.
Where the stretching or contraction of a hoist rope could create a hazard, chairs or other
suitable blocking shall be used to support conveyances at shaft landings before heavy
equipment or material is loaded or unloaded.
30 CFR 57.19000 - Application.
(a) The hoisting standards in this subpart apply to those hoists and appurtenances used for
hoisting persons. However, where persons may be endangered by hoists and appurtenances
used solely for handling ore, rock, and materials, the appropriate standards should be applied.
(b) Standards 57.19021 through 57.19028 shall apply to wire ropes in service used to hoist-(1) Persons in shafts and slopes underground;
(2) Persons with an incline hoist on the surface; or
(3) Loads in shaft or slope development when persons work below suspended loads.
(4) These standards do not apply to wire ropes used for elevators.
(c) Emergency hoisting facilities should conform to the extent possible to safety requirements
for other hoists, and should be adequate to remove the persons from the mine with a minimum
of delay.
30 CFR 57.19001 - Rated capacities.
Hoists shall have rated capacities consistent with the loads handled and the recommended
safety factors of the ropes used.
30 CFR 57.19002 - Anchoring.
Hoists shall be anchored securely.
30 CFR 57.19003 - Driving mechanism connections.
Belt, rope, or chains shall not be used to connect driving mechanisms to man hoists.
30 CFR 57.19004 - Brakes.
Any hoist used to hoist persons shall be equipped with a brake or brakes which shall be capable
of holding its fully loaded cage, skip, or bucket at any point in the shaft
30 CFR 57.19005 - Locking mechanism for clutch.
The operating mechanism of the clutch of every man-hoist drum shall be provided with a
locking mechanism, or interlocked electrically or mechanically with the brake to prevent
accidental withdrawal of the clutch.
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30 CFR 57.19006 - Automatic hoist braking devices.

Automatic hoists shall be provided with devices that automatically apply the brakes in the
event of power failure.
30 CFR 57.19007 - Overtravel and overspeed devices.
All man hoists shall be provided with devices to prevent overtravel. When utilized in shafts
exceeding 100 feet in depth, such hoists shall also be provided with overspeed devices.
30 CFR 57.19008 - Friction hoist synchronizing mechanisms.
Where creep or slip may alter the effective position of safety devices, friction hoists shall be
equipped with synchronizing mechanisms that recalibrate the overtravel devices and position
indicators.
30 CFR 57.19009 - Position indicator.
An accurate and reliable indicator of the position of the cage, skip, bucket, or cars in the shaft
shall be provided.
30 CFR 57.19010 - Location of hoist controls.
Hoist controls shall be placed or housed so that the noise from machinery or other sources will
not prevent hoistmen from hearing signals.
30 CFR 57.19011 - Drum flanges.
Flanges on drums shall extend radially a minimum of 4 inches or three rope diameters beyond
the last wrap, whichever is the lesser.
30 CFR 57.19012 - Grooved drums.
Where grooved drums are used, the grooves shall be of suitable size and pitch for the ropes
used.
30 CFR 57.19014 - Friction hoist overtravel protection.
In a friction hoist installation, tapered guides or other approved devices shall be installed above
and below the limits of regular travel of the conveyance and arranged to prevent overtravel in
the event of failure of other devices.
30 CFR 57.19017 - Emergency braking for electric hoists.
Each electric hoist shall be equipped with a manually-operable switch that will initiate
emergency braking action to bring the conveyance and the counterbalance safely to rest. This
switch shall be located within reach of the hoistman in case the manual controls of the hoist
fail.
30 CFR 57.19018 - Overtravel by-pass switches.
When an overtravel by-pass switch is installed, the switch shall function so as to allow the
38 | P a g e

conveyance to be moved through the overtravel position when the switch is held in the closed
position by the hoistman. The overtravel by-pass switch shall return automatically to the open
position when released by the hoistman.
30 CFR 57.19021 - Minimum rope strength.
At installation, the nominal strength (manufacturer's published catalog strength) of wire ropes
used for hoisting shall meet the minimum rope strength values obtained by the following
formulas in which "L" equals the maximum suspended rope length in feet:
(a) Winding drum ropes (all constructions, including rotation resistant).
For rope lengths less than 3,000 feet: Minimum Value=Static Load x (7.0--0.001L)
For rope lengths 3,000 feet or greater: Minimum Value=Static Load x 4.0.
(b) Friction drum ropes.
For rope lengths less than 4,000 feet: Minimum Value=Static Load x (7.0--0.0005L)
For rope lengths 4,000 feet or greater: Minimum Value=Static Load x 5.0.
(c) Tail ropes (balance ropes).
Minimum Value=Weight of Rope x 7.0
30 CFR 57.19022 - Initial measurement.
After initial rope stretch but before visible wear occurs, the rope diameter of newly installed
wire ropes shall be measured at least once in every third interval of active length and the
measurements averaged to establish a baseline for subsequent measurements. A record of the
measurements and the date shall be made by the person taking the measurements. This record
shall be retained until the rope is retired from service.
30 CFR 57.19023 - Examinations.
(a) At least once every fourteen calendar days, each wire rope in service shall be visually
examined along its entire active length for visible structural damage, corrosion, and improper
lubrication or dressing. In addition, visual examination for wear and broken wires shall be made
at stress points, including the area near attachments, where the rope rests on sheaves, where
the rope leaves the drum, at drum crossovers, and at change-of-layer regions. When any visible
condition that results in a reduction of rope strength is present, the affected portion of the
rope shall be examined on a daily basis.
(b) Before any person is hoisted with a newly installed wire rope or any wire rope that has not
been examined in the previous fourteen calendar days, the wire rope shall be examined in
accordance with paragraph (a) of this section.
(c) At least once every six months, nondestructive tests shall be conducted of the active length
of the rope, or rope diameter measurements shall be made-(c)(1) Wherever wear is evident;
(c)(2) Where the hoist rope rests on sheaves at regular stopping points;
39 | P a g e

(c)(3) Where the hoist rope leaves the drum at regular stopping points; and
(c)(4) At drum crossover and change-of-layer regions.
(d) At the completion of each examination required by paragraph (a) of this section, the person
making the examination shall certify, by signature and date, that the examination has been
made. If any condition listed in paragraph (a) of this section is present, the person conducting
the examination shall make a record of the condition and the date. Certifications and records of
examinations shall be retained for one year.
(e) The person making the measurements or nondestructive tests as required by paragraph (c)
of this section shall record the measurements or test results and the date. This record shall be
retained until the rope is retired from service.
30 CFR 57.19024 - Retirement criteria.
Unless damage or deterioration is removed by cutoff, wire ropes shall be removed from service
when any of the following conditions occurs:
(a) The number of broken wires within a rope lay length, excluding filler wires, exceeds either-(a)(1) Five percent of the total number of wires; or
(a)(2) Fifteen percent of the total number of wires within any strand.
(b) On a regular lay rope, more than one broken wire in the valley between strands in one rope
lay length.
(c) A loss of more than one-third of the original diameter of the outer wires.
(d) Rope deterioration from corrosion.
(e) Distortion of the rope structure.
(f) Heat damage from any source.
(g) Diameter reduction due to wear that exceeds six percent of the baseline diameter
measurement.
(h) Loss of more than ten percent of rope strength as determined by nondestructive testing.
30 CFR 57.19025 - Load end attachments.
(a) Wire rope shall be attached to the load by a method that develops at least 80 percent of the
nominal strength of the rope.
(b) Except for terminations where use of other materials is a design feature, zinc (spelter) shall
be used for socketing wire ropes. Design feature means either the manufacturer's original
design or a design approved by a registered professional engineer
(c) Load end attachment methods using splices are prohibited.
30 CFR 57.19026 - Drum end attachment.
(a) For drum end attachment, wire rope shall be attached-(1) Securely by clips after making one full turn around the drum spoke;
(2) Securely by clips after making one full turn around the shaft, if the drum is fixed to the shaft;
40 | P a g e

or
(3) By properly assembled anchor bolts, clamps, or wedges, provided that the attachment is a
design feature of the hoist drum. Design feature means either the manufacturer's original
design or a design approved by a registered professional engineer.
(b) A minimum of three full turns of wire rope shall be on the drum when the rope is extended
to its maximum working length.
30 CFR 57.19027 - End attachment retermination.
Damaged or deteriorated wire rope shall be removed by cutoff and the rope reterminated
where there is-(a) More than one broken wire at an attachment;
(b) Improper installation of an attachment;
(c) Slippage at an attachment; or
(d) Evidence of deterioration from corrosion at an attachment.
30 CFR 57.19028 - End attachment replacement.
Wire rope attachments shall be replaced when cracked, deformed, or excessively worn.
30 CFR 57.19030 - Safety device attachments.
Safety device attachments to hoist ropes shall be selected, installed, and maintained according
to manufacturers' specifications to minimize internal corrosion and weakening of the hoist
rope.
30 CFR 57.19035 - Headframe design.
HEADFRAMES AND SHEAVES
All headframes shall be constructed with suitable design considerations to allow for all dead
loads, live loads, and wind loads.
30 CFR 57.19036 - Headframe height.
Headframes shall be high enough to provide clearance for overtravel and safe stopping of the
conveyance.
30 CFR 57.19037 - Fleet angles.
Fleet angles on hoists installed after November 15, 1979, shall not be greater than one and onehalf degrees for smooth drums or two degrees for grooved drums.
30 CFR 57.19038 - Platforms around elevated head sheaves.
Platforms with toeboards and handrails shall be provided around elevated head sheaves.
30 CFR 57.19045 - Metal bonnets.
CONVEYANCES
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Man cages and skips used for hoisting or lowering employees or other persons in any vertical
shaft or any incline shaft with an angle of inclination of forty-five degrees from the horizontal,
shall be covered with a metal bonnet.
30 CFR 57.19055 - Availability of hoist operator for manual hoists.
HOISTING PROCEDURES
When a manually operated hoist is used, a qualified hoistman shall remain within hearing of the
telephone or signal device at all times while any person is underground.
30 CFR 57.19056 - Availability of hoist operator for automatic hoists.
When automatic hoisting is used, a competent operator of the hoist shall be readily available at
or near the hoisting device while any person is underground.
30 CFR 57.19057 - Hoist operator's physical fitness.
No person shall operate a hoist unless within the preceding 12 months he has had a medical
examination by a qualified, licensed physician who shall certify his fitness to perform this duty.
Such certification shall be available at the mine.
30 CFR 57.19058 - Experienced hoist operators.
Only experienced hoistmen shall operate the hoist except in cases of emergency and in the
training of new hoistmen.
30 CFR 57.19061 - Maximum hoisting speeds.
The safe speed for hoisting persons shall be determined for each shaft, and this speed shall not
be exceeded. Persons shall not be hoisted at a speed faster than 2,500 feet per minute, except
in an emergency.
30 CFR 57.19062 - Maximum acceleration and deceleration.
Maximum normal operating acceleration and deceleration shall not exceed 6 feet per second
per second. During emergency braking, the deceleration shall not exceed 16 feet per second
per second.
30 CFR 57.19063 - Persons allowed in hoist room.
Only authorized persons shall be in hoist rooms.
30 CFR 57.19080 - Hoisting tools, timbers, and other materials.
When tools, timbers, or other materials are being lowered or raised in a shaft by means of a
bucket, skip, or cage, they shall be secured or so placed that they will not strike the sides of the
shaft.
30 CFR 57.19081 - Conveyances not in use.
When conveyances controlled by a hoist operator are not in use, they shall be released and the
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conveyances shall be raised or lowered a suitable distance to prevent persons from boarding or
loading the conveyances.
30 CFR 57.19083 - Overtravel backout device.
A manually operated device shall be installed on each electric hoist that will allow the
conveyance or counterbalance to be removed from an overtravel position. Such device shall not
release the brake, or brakes, holding the overtravelled conveyance or counterbalance until
sufficient drive motor torque has been developed to assure movement of the conveyance or
counterbalance in the correct direction only.
30 CFR 57.19090 - Dual signaling systems.
There shall be at least two effective approved methods of signaling between each of the shaft
stations and the hoist room, one of which shall be a telephone or speaking tube.
30 CFR 57.19091 - Signaling instructions to hoist operator.
Hoist operators shall accept hoisting instructions only by the regular signaling system unless it is
out of order. In such an event, and during other emergencies, the hoist operator shall accept
instructions to direct movement of the conveyances only from authorized persons.
30 CFR 57.19093 - Standard signal code.
A standard code of hoisting signals shall be adopted and used at each mine. The movement of a
shaft conveyance on a "one bell" signal is prohibited.
30 CFR 57.19094 - Posting signal code.
A legible signal code shall be posted prominently in the hoist house within easy view of the
hoistmen, and at each place where signals are given or received.
30 CFR 57.6204 - Hoists.
(a) Before explosive material is transported in hoist conveyances-(1) The hoist operator shall be notified; and
(2) Hoisting in adjacent shaft compartments, except for empty conveyances or counterweights,
shall be stopped until transportation of the explosive material is completed.
(b) Explosive material transported in hoist conveyances shall be placed within a container which
prevents shifting of the cargo that could cause detonation of the container by impact or by
sparks. The manufacturer's container may be used if secured to a nonconductive pallet. When
explosives are transported, they shall be secured so as not to contact any sparking material.
(c) No explosive material shall be transported during a mantrip.

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Appendix F - Applicable OSHA Regulations

1926.251(c)
Wire rope.
1926.251(c)(1)
Tables H-3 through H-14 shall be used to determine the safe working loads of various sizes and
classifications of improved plow steel wire rope and wire rope slings with various types of
terminals. For sizes, classifications, and grades not included in these tables, the safe working
load recommended by the manufacturer for specific, identifiable products shall be followed,
provided that a safety factor of not less than 5 is maintained.
1926.251(c)(2)
Protruding ends of strands in splices on slings and bridles shall be covered or blunted.
1926.251(c)(3)
Wire rope shall not be secured by knots, except on haul back lines on scrapers.
1926.251(c)(4)(i)
An eye splice made in any wire rope shall have not less than three full tucks. However, this
requirement shall not operate to preclude the use of another form of splice or connection
which can be shown to be as efficient and which is not otherwise prohibited.
1926.251(c)(4)(ii)
Except for eye splices in the ends of wires and for endless rope slings, each wire rope used in
hoisting or lowering, or in pulling loads, shall consist of one continuous piece without knot or
splice.
1926.251(c)(4)(iii)
Eyes in wire rope bridles, slings, or bull wires shall not be formed by wire rope clips or knots.
1926.251(c)(4)(iv)
Wire rope shall not be used if, in any length of eight diameters, the total number of visible
broken wires exceeds 10 percent of the total number of wires, or if the rope shows other signs
of excessive wear, corrosion, or defect.
1926.251(c)(5)
When U-bolt wire rope clips are used to form eyes, Table H-20 shall be used to determine the
number and spacing of clips.

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Table H-20:
1926.251(c)(5)(i)
When used for eye splices, the U-bolt shall be applied so that the "U" section is in contact with
the dead end of the rope.

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Appendix G - Applicable Arizona Mining Regulations

27-348. Shaft stations
Stations or levels shall have a passageway around the working shaft so that crossing over the
hoisting compartments may be avoided. Sumps shall be securely covered. At shaft stations a
gate or guard rail shall be provided and kept in place across the shaft, except when a cage, skip
or bucket is being loaded, but may be temporarily removed for repairs or other operations if
proper precaution is taken to prevent danger to persons. The top of the shaft shall be protected
by a substantial gate or guard rail.
27-351. Hoists; operator; indicator
A. No person addicted to intoxicating liquors or drugs, or under eighteen years of age shall be
employed as a hoisting engineer.
B. All power hoisting machinery used in hoisting from or lowering employees and materials into
mines, except for prospect shafts not exceeding three hundred feet in depth, shall be equipped
with an indicator placed near and in clear view or hearing of the engineer. The indicator shall be
in addition to marks on the rope, cable or drum.
C. It is unlawful to hoist or lower persons from or into a mine at a speed greater than fifteen
hundred feet per minute, but the inspector may designate a lesser speed than fifteen hundred
feet per minute in a shaft, if in his opinion a greater speed is unsafe, or a greater speed if in his
opinion particular shafts and hoist conditions so warrant.
27-352. Inspection and construction of hoists
A. Hoisting machinery, cables and sheaves shall be inspected once every twenty-four hours by a
competent person appointed by the operator for that purpose, and the person making the
inspection shall immediately report in writing to the operator all defects found.
B. Ropes or cables used for hoisting purposes shall be of approved quality and manufacture. In
shafts and winzes over two hundred feet deep, wire ropes or cables only shall be used for
hoisting purposes.
C. Head frames where persons are hoisted at a speed of over two hundred fifty feet per minute
and where more than twenty-five persons are employed shall be constructed to allow at least
twenty-five feet above the hoist landing stage in which the cage, skip or bucket can travel freely
in case of an overwind.
27-358. Signaling apparatus
A. Every shaft and each compartment thereof used for hoisting which exceeds fifty feet in
depth, and not exempted in writing by the inspector, shall be provided with an efficient means
of interchanging distinct and definite signals between the top of the shaft and the lowest level
from which hoisting is being done, and the various intermediate levels for the time they are in
use.
B. The signaling apparatus shall be either wire or cable actuating a bell, whistle, speaking tube,
telephone, electric or electronic system, or two or more of them.
C. Only those employees and supervisors authorized by the operator shall be permitted to ring
any shaft or station bells.
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Appendix H - Stantec Proposal

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April 6, 2011
San Xavier Hoist Operators Manual

Team 7
Team 7
Stephenie Mirka, Scott Shields,
Dana Specht, and Andrew Swazey

MNE 498

Contents
Acknowledgements ............................................................................................... 1
San Xavier Mining Laboratory Safe Hoist Operating Procedures ............................ 2
San Xavier Mining Laboratory Hoist Bell Signals..................................................... 3
Quick Start Guide ................................................................................................... 4

ii

Acknowledgements
Team 7 would like to thank Mike Beus from SafeHoist for his continued support
of hoisting projects at the San Xavier Mining Laboratory. This manual would not
be possible without his support.

San Xavier Mining Laboratory Safe Hoist Operating Procedures

1. Only authorized persons shall be in hoist rooms or hoist cabs.
2. Personnel shall not ride loaded skip decks, cage decks, or buckets with
muck, supplies, materials, or tools other than small hand tools.
3. When a manually operated hoist is used, a qualified hoist operator shall
remain within hearing of the telephone or signal device at all times while
any person dependent on that hoist is in the mine.
4. Only experienced hoist operators shall operate a hoist except in case of
emergency and when new operators are being trained.
5. When personnel are hoisted in buckets, rope speed shall not exceed 500
ft/min and shall not exceed 200 ft/min when approaching the intended
station or stopping point.
***Note: The hoistman shall respond to call signals for a cage, before presenting
the cage to a person on a level. Until the hoistman has responded to a signal,
thereby acknowledging the receipt of that signal, no person will attempt to signal
on the shaft bell system, nor shall any person attempt to load a cage until the
hoistman has acknowledged the receipt on the squawker.

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San Xavier Mining Laboratory Hoist Bell Signals

Cage Position Adjustment Signals:
Slow Bells Mean Move Cage Slowly
1 Bell - Stop Immediately
2 Bells - Lower Cage
3 Bells - Raise Cage
General Communication Signals:
5 Bells - Turn Air On/Off
7 Bells - Go to Mine Phone Immediately - Possible Emergency
Surface Cage Dispatching Signals:
1 Long Bell + 1 Bell + 1 Bell - Send Cage to Shaft Collar
1 Long Bell + 1 Bell + 2 Bells - Send Cage to 100 Level
1 Long Bell + 1 Bell + 3 Bells - Send Cage to 150 Level
1 Long Bell + 1 Bell + 4 Bells - Cage Released from Collar
100 Level Cage Dispatching Signals:
1 Long Bell + 2 Bells + 1 Bell - Send Cage to Shaft Collar
1 Long Bell + 2 Bells + 2 Bells - Send Cage to 100 Level
1 Long Bell + 2 Bells + 3 Bells - Send Cage to 150 Level
1 Long Bell + 2 Bells + 4 Bells - Cage Released from 100 Level
150 Level Cage Dispatching Signals:
1 Long Bell + 3 Bells + 1 Bell - Send Cage to Shaft Collar
1 Long Bell + 3 Bells + 2 Bells - Send Cage to 100 Level
1 Long Bell + 3 Bells + 3 Bells - Send Cage to 150 Level
1 Long Bell + 3 Bells + 4 Bells - Cage Released from 150 Level
***Note: Hoist Operator will not move cage unless all bell signals are understood
and a signal has been received from both the sending and receiving shaft stations.

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Quick Start Guide

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