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Trackless mining at the International NickelCompany of Canada, Limited
SYNOPSIS
by C. F. HEWS* (Visitor)
An account is given of the evolution and advantages of trackless equipment in the underground operations ofInternati?nal Nickel's Ontario Division, with special reference to fill-method mining, development practice, sub-level caving, and induced block caving. Details of maintenance, environmental control, and operator training arealso given.
SAMEVATTING
Daar word verslag gedoen oor die ontwikkeling en voordele van spoorlose uitrusting in die ondergrondse werk-saamhede van International Nickel se Ontario-afdeling met spesiale verwysing na ontginning volgens die opvul-metode, ontsluitingspraktyk, subvlakinstorting, en geinduseerde blokstorting. Daar word ook besonderhede inverband met onderhoud, omgewingsbeheer en die opleiding van operateurs verstrek.
INTRODUCTION
The mining operations of theOntario Division of the InternationalNickel Company are centred atSudbury, a city of 160000 popu-lation, located 200 miles north ofToronto, Ontario (Fig. 1). The com-pany currently operates elevenunderground mines and one open pitwithin 30 miles of Sudbury, themines being located round the rimof the geological formation known asthe Sudbury Basin (Fig. 2). Thereare also three standby mines andone developing mine in the Sudburyarea, and one operating mine atShebandowan near the city ofThunder Bay, Ontario.
In 1972, the mines produced16400000 tons of ore, 14700000tons from underground and thebalance from the open pit.
The main facilities for the ex-traction and refining of the metalscontained in the ore are also locatedin the Sudbury area. A nickel re-finery is located at Port Col borne onLake Erie. Fifteen elements are re-covered from the Sudbury ores:nickel, copper, iron, sulphur, gold,silver, cobalt, selenium, tellurium,platinum, palladium, iridium, rho-dium, ruthenium, and osmium.
In 1966, a major expansion pro-gramme was undertaken to meetincreasing market requirements. Co-inciding as it did with a severelabour shortage, a large portion ofthis expanded production had to beaccomplished through increasing pro-ductivity in tonl' per man shift in
*Manager, Maintenance, Mines and Mills(Ontario Division)
every phase of the operation.In the mining section of the Com-
pany, the first step to this end wasthe adoption of load-haul-dumpequipment in the ore-removal op-erations. The first such unit wasintroduced in March 1966. Sincethen, this programme has pro-gressed to the point where 67 percent of all underground ore pro-duction is handled by this type ofequipment. From the original 4 yd3capacity machine, we have expandedto a fleet of 190 machines of It, 2, 3,4, 5, and 8 yd3 capacity. These are
u s0
h500
--.J-MILES
1000I
being used in cut-and-fill, undercut-and-fill, shrinkage, caving and blast-hole stoping, as well as horizontaland ramp development.
Concurrently with the expandinguse of this equipment, a programmeto provide complementary drillingmachines that would improve drill-ing and breaking efficiency was alsoundertaken. This paper deals withthe evolution and advantages oftrackless equipment in the under-ground operations of InternationalNickel's Ontario Division. It specific-ally describes the applications in
A -CANADIAN SHIELD
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
Fig. I-The location ofSudbury
AUGUST 1973
SUDBURY DISTRICT
--
1\LI
MILES
~
//
"
Fig. 2- The Sudbury Basin
With this machine, 12 ft breastswere drilled and blasted; the freshlyexposed ground was rock boltedfrom the muckpile, the broken oreremoved, and then the cycle wasrepeated. It was necessary to have atleast three active stope faces tomaintain this cycle. The movingfrom face to face and the preparationor set-up time proved to be anappreciable percentage of the totalavailable machine time. To elimi-nate this unproductive time, it wasproposed to change to drilling up-holes, or 'uppers' as they arecommonly called.
This method was not new toInternational Nickel. The Company
the following:(1) fill-method mining,(2) development,(3) sublevel caving, and(4) induced block caving,and makes special reference to main-tenance, environmental control, andoperator training.
MECHANIZED EQUIPMENT INFILL-METHOD MINING
Cut-ana-fill StapesThe first low-profile, diesel-opera-
ted load-haul-dump unit was intro-duced in an interconnected group ofcut-and-fill stopes at Frood Mine inMarch 1966. Test results were en-couraging from the outset. Stepswere then taken to mechanize thedrilling operations with the in-tention of achieving similar im-provements in drilling and breakingefficiency.
The first drilling machine was re-ceived in March 1967. It was athree-boom unit capable of drillingfrom one set-up a complete cut-and-fill bench 28 ft wide and 10 ft highwith 12 ft horizontal holes. Usingsingle-pass steel, one operator coulddrill the complete face withoutleaving the controls except to changebits (Fig. 3). The unit was mountedon a four-wheeled, rubber-tyredchassis powered by a 66 hp air-cooled Deutz diesel engine. When inposition, it was connected to minewater and compressed-air lines tooperate the drills and hydraulicpump. The hydraulic pump was alsocapable of being powered by a take-off from the diesel motor.
2 AUGUST 197a
tried it in 1962 and 1963, usingseveral methods of drilling, hand-held stopers, airleg drills mountedon tripods, and leyner drills mountedon wagons. At that time our re-search established that holes in-clined at 65 degrees to the horizontalgave the optimum combination offragmentation and ground-controlconditions. The method provided abetter mining cycle by making thefour operations-drilling, blasting,rock bolting, and ore removal-in-dividually continuous and less inter-dependent. However, the 'uppers'method required more footagedrilled per unit broken. With thedrilling equipment then available,where one man operated one ma-chine, there was a reduction inproductivity due partly to the in-creased drilling and partly to thedifficulty of collaring holes at 65degrees without benefit of steelretainers. A mechanized unit wouldsolve these problems. The problemof having small pieces of looseground falling during the collaring ofholes is eliminated by the installationof welded wire-mesh head coverwith the rock bolts.
A simple change in the attachmentof the drills to the booms effectedthe conversion to a three-boom'uppers' machine (Fig. 4). The samesingle- pass steel was used to drill12 ft holes at 65 degrees, giving a
Fig. ]- Three-boom drilling machine
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
io it cut. An additional benefit re-sulted in that the throwing sidewaysof the blasted ore, instead of straightdown, made a much less compactedpile, which facilitated the loadingoperation.
Since the normal distance fromthe top of the fill to the roof of thestope before blasting is 9 ft, it wasnecessary for the drilling to be donebefore the fill was placed to accom-modate the single-pass 12 ft steel.There were two problems inherentin this situation. First, the 20 ft-high pillar walls were exposed un-supported for too long a period oftime, and, secondly, the unevenfloor condition left after the ore wasremoved made it difficult. to manoeu-vre the mobile drill.
Because of the success of themethod at Frood, a similar complexof 'uppers' drilled cut-and-fill stopeswas started at Levack. For thisapplication, a specially designed'uppers' rig (Fig. 5) was purchased.
Fig. 5-Specially designed 'uppers' rig
This-unit had two booms supporting4t in piston diameter drills on 8 ftguides mounted on an air-poweredfour-wheel chassis. It drilled 12 ft by2i in holes in two 6 ft passes, using1 in quarter-octagon steel. Thebottom of the guides was supportedby hydraulic pistons that extendedto the floor and provided goodstability. The advantages of theoperator's nearness to the drillswhile collaring the holes and theeasier manoeuvrability on thesmooth floor outweighed the dis-advantage of having to drill theholes in two passes.
For two years this unit was thestandard for this type of mining.During this time, some testing wasdone on small-hole 'uppers' rigs.This resulted in the adoption of theuse of a lightweight three-wheeledwagon supporting a bar on whichare mounted two 3i in piston dia-meter drills. The drills are mountedon two 6 ft cable feeds, pneumaticallypowered, with a 3 ft extensionfeature. The drill steel used is
i in hexagonal with tapered endsand It in bits (Fig. 6). The controlsfor the drills, feeds, and tractionair motor are located at the back,above the single steering wheel.Well suited for this particular appli-cation, these machines are easilydismantled and moved from stope toFig. 4- Three-boom 'uppers' drilling machine
JOURNAL OFTHE SO\lTHAFRICAN INSTITUTE OF MINING AND METALLURGY AUGUST 1973 3
Fig. 6-A small-hole 'uppers' rig
stope, and cost about 15 per centof the price of the large jumbos.
Cut-and-fill stope mucking iseffected by ST2A, ST4A, and ST8machines (Fig. 7). The choice ofmachine is dictated by the size of thestope or complex and the demands ofthe drilling, mucking, and fillingcycles. Generally, the 2 yd3 ma-chines are used in 'captive stopes'or small complexes, and the othersin the larger complexes.
The machines in the past haveoperated on a 10:1 ratio cementedsand floor. Of late we have beenworking successfully on 30:1 ratiofloors.
Cut-and-fill efficiency at ourLevack Mine in 1972 was 35 tonsper man-shift in mechanized stopes,compared with 22 tons per man-shiftin conventional stopes.
A mines-wide cost comparison fordrilling and mucking is shown inTable I.
4 AUGUST 1973
Undercut-ana-fill Stopes
In late 1969, three of our minesinitiated the use of load-haul-dumpequipment in undercut-and-fillstopes. These situations, all basi-cally similar, were multi-slice com-plexes with a common access forthe 1t yd3 unit. The productivity
in these stopes rose to 23 tons perman-shift from an average of 15 fornon-mechanized undercut-and-fillstopes.
Attempts to mechanize the drillingin these stopes have so far provedunsuccessful. In this application,size and manoeuvrability are im-portant considerations. The machinemust travel between timber posts11 ft apart and make 90-degree turnsfrom one 11 ft-wide passageway intoanother (Fig. 8). Also, the amount ofdriJIing for each blast-approxi-mately twenty 6 ft holes-is rela-tively small, making it difficult for amechanized unit to compete withhand-held airleg drills. To be ac-ceptable, such a machine should becapable of traveJIing to, setting up,and driJIing off two faces in a shift,with sufficient time remaining forthe operator to load the holes forblasting.
DEVELOPMENT PRACTICE
Current development practice intrackless-mining areas is to drivetramways 14 ft wide and 12 ft high,with drawpoints varying from 12 ftby 9 ft to 16 ft by 12 ft. Drill cross-cuts are driven 16 ft wide by 12 fthigh. Main tramways, where trucksare used, are driven 16 ft wide and10 or 12 ft high. Radius of curva-tures varies from 30 ft at drawpointturnoffs to 70 ft on main ramps andtramways. Minimum grade is usually4 per cent but may be as low as2 per cent; maximum grade is 20 percent.
Development driJIing is carriedout with three-boom jumbos (Fig. 9).Machines with 4t in piston diameterremain the standard, with 11 in
TABLE IDRILLING COSTS PER 10 FT" UNIT
DRILLING
HorizontalAir Leg
$1. 770.060.08
UppersTwo-boom
Jumbo$
1.040.110.210.111.47
ST8$
0.090.010.210.31
Labour costs ,Bit and steel costsDrill repairs. . . . . . .Drill rig repairs .........Total drilling. . . . . . . . . .. 1.91
MUCKING COSTS PER TONST2A
$0.300.020.600.92
Stopewagon$
1.200.140.060.241.64
ST4A$
0.130.010.350.49
Operating labour. . . . . . . . .Operating supplies. . . . . . . . .Repair labour and supplies. . . . .Total mucking ,....
Tons per operating hour. . . . . . 25 60 85
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
Fig. 7-Machine for cut-and-fill stope mucking
hexagonal steel and 1i in threaded development costs will be appreciat-bits. Booms with automatic parallel- ed.drill alignment and autom~tic feed In addition, the mechanization ofreturn are advantageous wIth less- th
.d ill ' h f th '.. e prImary l' mg p ase 0 IS
experIenced drillers. The jumbos. .h £ h 1 d
. d 66 hoperatIOn has been accomplIshed
ave our-wee rIve an p, . .,d bl f 1
.b '
wIth resultmg reductIOns in costsengmes, an are capa e 0 c Im mgthe 20-degree grades.
and labour ,requirement:". Because
Development mucking is carried of the large SIze of the drIfts and the
out with ST4A and ST5A Scoop- required drill-hole pattern, conven-
trams: the ST4A's are used on tional bar-and-arm supported long-
horizontal or short-ramp situations, hole drilling in sublevel caving is
and the ST5A's are used on main-ramp situations. Whenever the tram-ming distance exceeds 800 ft, theuse of trucks is recommended,
The development performanceusing three-boom jumbos has shownan appreciable improvement overthat with airleg drills, A crew offour men, who perform the drilling,blasting, rock bolting, and mucking,and the installation of air, water,and ventilation pipelines, is achiev-ing a productivity of 2,7 ft of ad-vance per labour shift. Comparativecosts with airleg drills are shown inTable n.
SUB LEVEL CAVING
The development phase for sub-level caving is essentially as des-cribed in the preceding section,Since the development stage ofsublevel caving accounts for 25 percent of the total ore removed in themethod, the importance of reduced
very inefficient. This has been re-placed by a mobile rig supportingtwo longhole drills (Fig. 10). Thedrill feeds have been lengthenedfrom 4 ft to 6 ft, thus reducing thenumber of extension-rod changes by50 per cent. The drills are capable ofdrilling parallel vertical holes up to16 ft apart and inclined holes to45 degrees from the vertical side-ways, and from 95 degrees down tohorizontal towards the front. Thejumbos are mounted on four-wheelvehicles with air-powered tractionmotors; a 4 in-diameter bull hosesupplies compressed air from themain air line.
Table In compares the costs ofdrilling with conventional and mech-anized longhole units on a standardsublevel-caving hole pattern.
Owing to inexperience and naturalresistance to change, the averageproductivity of the jumbos is not yetas high as expected. Our expectationthat an average performance inexcess of 400 ft per shift will be ob-tained is substantiated by the factthat some drillers are now con-sistently exceeding this target. In amine with a drilling programme of200 000 ft per month, the effect ofintroducing the two-boom jumboswould be a reduction of force re-quirements of 40 men and an annualsaving of $360 OOO-sufficient to pay
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
Fig. 8-An undercut-and-fill stope
AUGUST 1973 5
TABL:I~n()()MPARATIVE COSTS PER FOOT FOR 16 FT BY 10 FT DRIFTS
Airleg Drills$
Total labour ,... 42.01Drilling-Steel and bits. . . . . . . . . . . . . 4.78
Drill repair . . . . . . . . . . 4.16Jumbo repairs ,...
Total drilling supplies and repairs . . . . .ST4AScooptramrepairs. . . . . . . . . . . .Total labour and equipment costs . . . . .Feet per man-shift. . . . . . . . . . .
Three-boomJumbo
$27.83
5.354.459.46
19.267.52
54.612.70
8.947.52
58.4 71.71
TABLE IIISUB-LEVEL CAVING-COSTS PER FOOT OF DRILLING
Conventional$
Labour ., .,... 0.49Drill repairs 0.14Jumbo repairs .................Bits, rods, supplies ,...
Two-boomJumbo
$0.190.140.150.170.17
TOTAL 0.80
142
. . . . . 0.65. . . . . .Difference ..................Productivity per man-shift. . . . . . . .
0.15361
Fig. 9-A three-boom jumbo
off the added capital expense in getting these large chunks down tofifteen months. the brow, it is possible to drill and
blast them with a more efficientuse of explosives.INDUOED BLOOK OAVING
After the development is com-pleted, the use of mechanized equip-ment in caving operations carrieson into the production phase. Theload-haul-dump units remove thebroken ore that flows into the draw-points, allowing the larger chunksthat block the flow to come rightdown to the brow. Previously withslusher scrapers, these chunks veryoften hung up in the boxholes andwere required to be sand-blasted. By
Secondary drilling is done with a'mobile secondary muck conditioner'.This consists of a drill and boommounted on the front of a truck.The drill is a 3-k in piston diameterdrill on a 6 or 8 ft drill shell, which isattached to a modified back-hoeboom. The boom is capable of a170-degree swing and 90-degree lift,and the drill shell can swing 90degrees and dump 120 degrees. The
6 AUGUST 1973
truck carries a 210 fta/min com-pressor driven by the truck motor,and two 30-gallon water tanks,making the unit independent of air-and water-service lines.
The operating and maintenancecosts of the 'muck conditioners'have been more than offset byreduction in secondary-blastingcosts. In addition, and more difficultto assess, are the savings in reduceddamage to ventilation and otherinstallations by concussion from'sand blasts'. A significant laboursaving and less exposure to dust alsoresult from the fewer blasts andshorter waiting time for smoke toclear after the blasts. Equally im-portant is the greatly improvedsafety of this phase of the operation.
MAINTENANCE OF DIESELEQUIPMENT
The successful use of diesel-powered equipment in underground-mining operations requires a rigidadherence to a well-planned in-spection and maintenance program-me. Obviously, close co-operationand communication between Op-erating and Maintenance Depart-ments is necessary for the success ofsuch a programme.
The first line of maintenance isthe vehicle operator. At the be.ginning of each shift, the operatormakes an initial check of his vehicle,using a checklist, which is com-pleted, signed, and submitted tosupervision. Particular attention ispaid to the condition of brakes,engine, and machine and to theappearance of exhaust gases. Anyirregularities are reported immed-iately.
The Maintenance Departmentschedules each piece of diesel-powered equipment for inspectionand service once every two weeks.This schedule must be rigidly main-tained to ensure that each piece ofequipment is available on the day itis scheduled for and that sufficienttime is allowed to permit a thoroughinspection and the carrying out ofany required repairs.
Schedule I is the form used for theinspection and servicing of ST4Aand ST5A Scooptrams once everytwo weeks, and Schedule II theform for the 6-week, 18-week, and
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
Fig. IO-A mobile rig supporting)wo longhole drills
annual inspection and servicing of Enginethe Scooptrams. It is important to Stall speed rev/min and full-
,note that the servicing intervals speed no-load rev/min must behave been established and revised, checked and maintained. The maxi-based on detailed investigations. mum allowable stall speed at fullThese forms cover the inspection of throttle for the ST4A engine isthe complete machine and include 1850 rev/min, and the full-speedthe following major items: no-load is 2300 rev/min.(a) air-intake system, Fuel System(b) exhaust system, It is important that only perfectly(c) engine, clean fuel is supplied to the fuel-(d) fuel system, injection pump and fuel injectors.(e) brakes, and The fuel at present in use has the(f) steering. following specifications:
Air-intake System Sulphur, % by massA decision was made to convert Viscosity, CS @ 100°F
the air cleaner from the oil-bath Cloud point, oftype to the dry type. The dry type Pour point, ofis more efficient: it reduces air- Final boiling point, ofcleaner maintenance and extends Brakesthe interval between engine-oil Brakes must be maintained andchanges. adjusted to specifications and tested
Exhaust System against engine power.The exhaust gases are passed Steering
through an oxy-catalytic scrubber All hoses, cylinders, and steeringfilled with Type A-316 catalytic controls must be thoroughly checkedpellets, roughly spherical in shape and maintained.
d / * * *an an average 3 16 in in diameter. A proper maintenance programmeIt is important that the temperature conscientiously performed with ade-of the exhaust gases at the scrubber quate follow-up, coupled with theinlet is over 500 o F for the efficient required ventilation programme, isoxidation of most of the toxic gases essential to the safe and efficientand carbon particles in the engine operation of diesel equipment.exhaust. Therefore, it is very im-portant that diesel engines are notrun at idle speeds, except for veryshort periods of time (5 minutes).
0,181,66-38-35565
MINE VENTILATIONThe Mines Branch of the Ontario
Ministry of Natural Resources re-
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
quires a minimum of 75 ft3/min ofventilating air per maximum brakehorsepower in all areas of dieseloperations. The ventilation instal-lations for diesel engines in ourmines are designed to supply 100ft3/min per brake horsepower inorder to guarantee that ventilationexceeds the minimum requirement.
During the last six years, thetotal volume of fresh air supplied toour mines has been increased from3,3 to 5,5 million ft3/min. Theaverage volume of air supplied perton hoisted per day has been raisedfrom 50 to 80 ft3/min, which has theadditional benefit of faster smokeclearance and improved dust control.
Mechanical ventilation systemsare provided for all diesel-powereddevelopment opera tions. Su pplement-ary systems are provided at alldiesel ore-extraction operations, ex-cept those ventilated directly by themain fans. For development withdiesel equipment, 170 electric aux-iliary fans have been instaHed,totalling 4500 hp and handling atotal of 2400000 ft3/min. For dieselore-extraction, 85 electric boosterfans are in use, totalling 1160 hpand handling 1 900000 ft3/min.
The ventilation staff is responsiblefor making the weekly gas tests andvolume survey at each diesel-powered machine, as required by theMines Branch. A recent summary ofour tests for carbon monoxide in theundiluted engine exhaust shows that96 per cent of the tests on theL.H.D. machines (load-haul-dump)and teletrams are below 300 p.p.m.,on locomotives are below 800 p.p.m.,and on drills, tractors, etc. are below1000 p.p.m. This compares withthe maximum carbon monoxidecontent aHowed by the Mines Branchof 1500 p.p.m.
The results of the other weeklytests made are as follows:
1. Adjacent to the engine (at theoperator just downstream)(a) Carbon monoxide-95 per
cent from trace to 5 p.p.m.(max. allowable 50 p.p.m.)
(b) Nitrogen dioxide-95 per centfrom trace to 1 p.p.m. (max.allowable 5 p.p.m.)
(c) Aldehydes*-95 per cent fromnil to trace (max. allowable2 p.p.m.)
AUGUST 1973 7
2. In the exhaust air (from the area)(a) Carbon monoxide-98 per
cent from trace to 5 p.p.m.(max. allowable 20 p.p.m.)
(b) Carbon dioxide*-96 per centfrom 400 to 1 000 p.p.m.(max. allowable 5 000 p.p.m.).
*Note-Weekly testing for aldehydesand carbon dioxide was dis-continued in January 1972.
The results of all weekly tests ateach mine are recorded in a speciallog book kept in the foreman'soffice at the collarhouse. These areinspected by the mining engineers ofthe Mines Branch.
In addition, all mine foremen carrya Drager or Auer gas detector andcarbon monoxide tubes. On the8 to 4 shift, the foremen take onetest at the operator of each dieselhaulage unit during each shift. If ahigh reading (approaching 50 p.p.m.)is obtained, the diesel engine isturned off until the ventilationsystem is checked and/or the engineis inspected by mechanics. Thesesupervisors record the results of alltests made in a special log book-also kept in the foreman's office.
GRAVIMETRIC DUSTSAMPLING
For the past two years, testworkwith personal gravimetric dustsamplers (Casella), collecting therespirable portion of the airbornedust on silver membrane filters, hasbeen carried out in a number ofOntario Mines. This work wasfinanced by the McIntyre ResearchFoundation, with direct assistancefrom the Federal Mines Branch atElliot Lake and the Mines AccidentPrevention Association of Ontario.
Recently a research engineer onour staff has been using two sets ofthis equipment to take gravimetricsamples on L.H.D. operators in ourmines. Direct supervision was main-tained during the time the operatorswore the samplers, and the flowratewas checked during the samplingperiod as well as before and after.The total mass of the sample, andthe mass after being heated to1050°F, for the removal of com-bustibles, were measured. Results todate are as follows.1. Initially, the filters used were
25 mm in diameter. A total of 20samples was obtained. Averagesampling period was 3 hours all ofworking time. Results: total
8 AUGUST 1973
respirable dust 2,9 mg/m3, com-bustibles 56 %=1,6 mg/m3, rockdust=1,3 mg/m3.
2. Filters 37 mm in diameter wereobtained, and fifteen 8-hoursamples were taken from collarto collar. Results: total respirabledust 2,0 mg/m3, combustibles75 %=1,5 mg/m3, rock dust=0,5mg/m3.
3. To obtain figures on the back-ground combustibles, ninesamples were taken on driller:;;and slushermen in non-dieselareas. Results: total respirabledust 0,9 mgfm3, combustibles50 %=0,45 mg/m3, rock dust0,45 mg/m3.
Thus the indications are that thecarbon particles in the air from ourL.H.D. exhausts are in the range of1 to 1,2 mg/m3.
From the experience gained overthe last seven years, it is our opinionthat the successful use of diesel-powered equipment in underground-mining operations depends to alarge extent on a programme thatincludes all the following factors:(1) the choice of clean-burning diesel
engines and clean fuel to mini-mize the toxic fumes produced,
(2) the use of oxy-catalytic exhaustscrubbers to eliminate most ofthe toxic gases in the engineexhaust and the odours normallyassociated with diesel engines,
(3) proper maintenance of engines,air-intake filters, exhaust scrub-bers, brakes, and steering,
(4) adequate ventilation throughoutall sections of the diesel-operat-ing areas, and
(5) daily checks on atmosphericconditions at each diesel haulageunit, in addition to the completeweekly tests required by theMines Branch.
TRAINING OF OPERATORSAND MECHANICS
Thorough operator and mechanictraining is essential to the safe andefficient operation of trackless equip-ment.
Prospective miners, when hired,pass through a two-phase trainingprogramme. In phase one, initialtraining of one week's duration isconducted at an induction centreand introduces the man to theunderground environment. Phasetwo is carried out at the mine towhich he is allocated, and consists of
a course of instruction for a specificwork classification. In both phasesthe new miner must pass proficiencytests. In the case of a Diesel Loader-man, an applicant is given a two-week training course. The trainee isunder the guidance of and in-structed by a designated instructor.His progress is followed and checkedby the supervisor in charge. At theend of the training period the success-ful applicant must pass a Qualifi-cation Test for Diesel Loadermen.
The Company provides a three-year Garage Mechanic ApprenticeProgramme as part of the overallTrades Training Programme. Suc-cessful applicants must pass anaptitude test and are graduates ofOntario Secondary School Grade 12or equivalent. The apprentice pro-gramme includes formal classroomtraining as well as practical ex-perience.
The Company also hires certifiedclass-A motor-vehicle repairers asgarage mechanics.
A continuous follow-up is carriedout for both operators and mech-anics through our ongoing safetyprogramme. In addition, an ex-tensive year-long upgrading pro-gramme is currently being conductedfor LH.D. operators, mechanics,and supervisors on the completescope of operation and maintenanceof trackless equipment. It is ex-pected that this portion of theoverall training will be updated andongoing as modifications and im-provements are made to currentequipment and as new types ofequipment are introduced to themines.
CONCLUSION
The following list of tracklessequipment currently in use in theOntario Division mines will providean appreciation of the degree of ourcommitment to this concept:
Stope Wagon 27Two-boom Stope Jumbo 9Three-boom Drift Jumbo 34Fan Drill 25Secondary Drill Jumbo 26Jarco . 13ST2A 45ST3A 2ST4A 93ST5A 17ST8A 20Teletram 14
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
- --ENGINE
Clean engine and entire unit
Check valve clearance .010"
Check compressor & alternator belts
Check oil/air/fuelleaks (running)
Change oil in fuel pump HD30
Take crankcase oil sample (600 Hr.)
Change crankcase oil HD 30 (200 Hr.)
Change air-cleaner elements
Check engine mounts
Check cooling blower & belt
Check engine Shut off rod
Check exhaust system (top scrubber)
Check cowlings
Check engine-warning system
Check air starter & grease
Fill air-starter oiler
Clean air starter, filter & screen
Test engine over temp. switches
Check fuel pump seals
Change all filters according to INCO Diesel service tag
TORQUE CONVERTER & TRANSMISSION
Check oil level and for leaks
Check for oxidation & colour
Check all transmission hoses (run)
Check mountings
Check controls (running)
Check neutral switch
MECHANIC'S TEST
Test-drive unit
Brake-test unit on grade
Stop-distance service brake Ft.
Stop-distance emergency brake Ft.
Disc-brake test
-HYDRAULIC SYSTEM
Check for leaks & oil level (running)
Check for oxidation, colour & cuttings
ICheck tank filter & O-Rings
Check hoses & cylinders for leaks & damage (operating)
Check dump & hoist controls
Check steering controls
Check for tank & filter damage
AXLES & DRIVELINES
Check all drivelines & U-Joints
Check tie-bolts
Check oscillating axle
Grease oscillating axle
Check differentials & planetaries
Adjust air brakes to ]' travel
Adjust hydraulic brake 020-025"
Expander tube type clearance (no less 1/8 ')
Check brake "uid container fr. & rr.
Check disc brake
Check wheel nuts & studs
Record tyre number & % wear:
LF
I
1--1 ::I
1--1-RR-I
BOOM & BUCKET
Check pins, bushings & locks
Check for cracks
MISCELLANEOUS
Check all gauges (running)
Top battery water & clean terminals
Check compressor discharge hose remove check valve
Drain water from air tanks
Test idle, no load, & stall speed
R.P.M.I U U [
Lubricate complete unit
andThe introduction of this equip-ment was necessary because of ashortage of labour and the necessityto improve efficiencies and reducecosts, coupled with our desire toimprove working conditions andsafety.
Continued success in the use of
this equipment depends on thefollowing:
(1) good engineering design forproper application of equipment,
(2) ongoing co-operation with manu-
facturers to improve equipment,
(3) good employee training, and
SCHEDULE IFORTNIGHTLY INSPECTION AND SERVICING OF SCOOPTRAMS
(4) proper maintenancevironmental control.
We believe that the result of suchan outlook will be further increasedproductivity by well-trained, satis-fied employees working in a saferenvironment.
I
Tag and Block VehicleRecord Inspection in Log Book
IUse Standard Check Off Code
II
viI
I
PM-527
I
en-
INCO Location
Equipment: No. .
Hour Meter 1=1=1=1=1=1I
2wkI
I
4wkI
I
6wkI
I
Code
I
xI
SCOOPTRAM SERVICE CHECK
LIST - ALL UNITSServiceChecked OK Need Repairs
Item Description
2
4
6
8
9
i 10
"I'll
'12
13
14
]5
]6
]7
18
]9
20
2
4
6
2
4
REMARKS:
I HEREBY CERTIFY TO THE ABOVE SERVICE & INSPECTION.
SERVICE INSPECTIONS ARE BOTH MANDATORY AND A
I
LEGAL REQUIREMENT -
Code Item Description
2
4
6
7
2
4
6
7
9
]0
]]
]2
2
2
3
4
5
6
DATE:....
MTCE. F'MAN.
EMP. SIGNATURE....
GENERAL F'MAN. PM DEPT.
No....
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY AUGUST 1973 9
ENGINE
Check valve clearance
Change engine over temperature switches
Clean fuel precleaner
Change primary fuel filter Code 37-16370
Change secondary fuel filter Code 23-14999
Take crankcase oil sample
Change crankcase oil (HD-30) Code 10-43560
Clean primary lube oil filter
Change secondary oil filter Code 23-14889
Check stall speed R.P.M.
Check full speed, no load R.P.M.
Remove brake drums to check-
Brake linings and shoes
Brake drums
Camshafts and bushings
Brake anchor pins
Brake cam rollers
Wheel bearings
Oil seals
Check brake activators
Check brake slack adjusters
Check quick-release valves
Check inversion valves
Check air-tank safety valves
Test air-tank hydrostatically
Repair and weld cracks
Paint entire machine
Change hydraulic oil Code 10-47280
Clean hydraulic oil tank
SCHEDULE ItINSPECTION AND SERVICING OF SCOOPTRAMS
PM-178 STANDARD PROCEDURE FORM SM-2232-B-3 REVISED 7/1/70
MINE:... MACHINE NO.:.
WAGNER ST 4A-5A SCOOPTRAM 600, 1800, & 5400 HOUR INSPECTION
. HOUR METER:...
PERFORMED BY: EMP. NO.:. NAME:.
AT EACH 600 HOUR INTERVAL or every 6 weeks, do 2oo-hour inspection as per form SM-2232-A3 and attend to the following additional items reporting in ap-propriate column.
. . d~ q ~0 ~ ::>
_1-
AT EACH 1800 HOUR INTERVAL, do 6O0-hour inspection and the following:
ENGINE
Adjust valve clearance to 0.010- cold
Check blower coupling rubbers
Change fuel injectors
TRANSMISSION
I:]:]] Change oil (Dexron) Code 10-12440
HYDRAULIC SYSTEM
I=!=I=I
Adjust bucket pressure to 1600 P.S.I.
Adjust steering pressure to 1500 P.S.I.
. DATE:..
. . d~ q ~0 ~ ;J TRANSMISSION
Change filter element Code 23-15186
HYDRAULIC SYSTEM
H=I=IClean tank filter
Change filter element Code 23-14983
BRAKES
==1Remove shields and inspect-
Brake lining
Brake-shoe anchor pins
Brake drums
===1
==]
AXLES-FRONT AND REAR
Change oil (GX-90) Code 10-34450
Check for metal particles in oil
Check bogie bearings
AT EACH 54oo-HOUR INTERVAL OR YEARLY, do 18oo-hour inspection and the following: Clean entire machine to inspect for cracks, repairs and paintings asnecessary:
ENGINE
I]:]] Change exhaust scrubber--
AXLES-FRONT & REAR
REMARKS:
16-SM-2232-B-3
MISCELLANEOUS
1==
[=
Signed :......... ......................................................................................................
Area Foreman
10 AUGUST 1973 JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
