Martin Reyes called the meeting to order and welcomed
everyone to Rapid City. Jed Jensen read the minutes and they were
approved as read. Jerry Endres provided the Treasure report. Jerry
mentioned that TXU has 3 BE 1350 draglines for sale as well as cable and
Martin Reyes announced future
Nov 17 – 19 2004 Reno, Nevada held at the Silver
May 8 – 10 2005 Calgary, Alberta held at the Sheraton
Nov 16 – 18 2005 Denver, Colorado held at the
Broke into 6 groups to discuss:
Problems and Solutions
Agenda items for next meeting
Soft Start for MG-Set – Jon
Vendela, Spring Creek Coal and Rick Scherer, Kennecott Energy
Gearless Drag/Hoist Drum System
– Michael Onsager, Bucyrus International
Spousal support award presented
Don Patterson of DCS presented the spousal support award
to Teri Marnell
Adjourn for Lunch
Panel Dealing with Excavator
Electrical Concerns-Rob Marnell, Bob Davis, Rich Hall, Gary Sorenson and
1. Multiple Processor Failures
Switch Failures on 5/40 Processor (Cordero 108 machine)
2. PLC Programming & A/B
Sorenson: Make sure
that hardware and software are compatible) Panelview vs. Panelview E.)
communication issues arise before any other issues.
3. Dragline Motor and Generator
Loops current unbalance Alarm; Broken Coupling Bolts
4. Neutral Adjustment – A/C as
accurate as PVN?
Casson: A/C is as
good as PVN and also somewhat safer.
Hall: A/C finds
symmetrical neutral – OK for Forward/reverse – single direction machines
be better set.
5. Would Laser Alignment be
more accurate than feeler gauges on MG sets?
necessarily, depends on circumstances.
6. What is the physical process
by which brushes get glued to the brush box?
Hall: T416 brushes
– resin will come out with heat and glue to box.
7. What electrically happens
when brush is glued?
Hall: brush will
not run on the comm. and a flashover will result.
8. What is the tolerance
between the brush and box?
Hall: +0 on
thickness and -.004 in direction of rotation; width +0 to -.015
9. Distance between brush box
Hall: Speced. By
motor manufacturer – GE .070” - .090”
10. Brush Pigtails – Story of
QD’s, the hows and whys.
11. Sleeving on pigtails of
Hall: There are
different types of insulating materials.
12. A/B PLC Hardware =
Equipment Types compared
Davis: Compared SLC
and PLC with MicroLogix
13. Marnell: showed pictures of
a CT that had an open secondary – melted.
14. Q: Talked about c/o of
brushes and seating them in (blower)
Hall: use pre-radiused
brushes, shouldn’t need to seat. If only changing one brush. 100%
leading to trailing edge
& 80% overall seating is acceptable.
15. How about light loading of
Hall: Low voltage
load better than light load.
16. What is the recommendation
for cold starting of MG sets?
instruction book has a paragraph that describes it.
Suggests heat on the pedestal oil. 8 hours or so of downtime, either
roll it or fill
reservoir or add some
oil prior to starting.
Hall: Oil must be
liquid, (heat pedestals); waste of time to pour it in on tip of
bearings. Oil only
counts on inside
diameter of bearing.
17. Discussion of generator
field overcurrent relay trip.
Marnell: Found sing
MG set slowing down when demand put on swing motors. Cause: B.O.
18. PLC Rack – 24v Power Supply
– 3 DC cards failed internally.
Marnell: found a
24v propel alarm tied into power supply wires had rubbed and were
19. PLC Rack – Continual
output triac that drove a sonalert – shorted triac – denergized –
sequence over and over.
20. R. Scherer: How do OEMs
size a Sync Motor on a dragline MG set?
Marnell: will as
OEM (Horvath or Baade) to answer tomorrow.
21. What is the magic number
for scan time before it affects operation of PLC on an excavator?
Sorenson: 100 msec
on PLC is good, has seen networks go as slow as 250 msec.
22. How do you test
signals between processors (using real time clock) and read out actual
it take for signal to
23. Triac Outputs
Davis: has seen
where people have tried to switch DC with triacs…doesn’t work.
Mine Flood Warning Systems-CFR
780 – Ted Lapis, Automation Electronics
Meeting adjourned for the day
Friday May 14
Meeting called to Order
Summary of group discussions
held on Thursday
Commutator Rebuild on Motors
and Generators – Laura Williams and Shawn Lyke, ICC International
Motor Protection - Dennis
Carrol, Kip Larson Symcom
Electrical Code Testing – Steve
Arne, Arne Electro-Tech.
WMEA 2004 Soft-Start On
Vendella at Spring Creek Coal stated that they have passed a Rio Tinto safety
audit better than anyone in North America so far.
Al Furness with
Bingham Canyon has gone 2 million man hours without a lost time accident.
Craig Russell of
Decker coal stated that they have gone 400 days without a reportable accident.
from Cordero Rojo Mine talked about the Take 5 program at Cordero.
talked about the simulator that Kennecott Energy Corporation purchased.
Currently using a module for haul truck operators with plans to extend use to
other pieces of equipment.
Al Furness talked
about the SMAT audits they use to ensure that everyone is working safely.
Supervisors are required to do two per week. Also talked about the lock boxes
they use. Box is set in front of machine lock has to be applied before
Cordero uses a
lockout board set outside of draglines during major outages. Used to lock
out particular motions on machine. Also talked about the work permits they
use when working with contractors.
Don Paterson of
DCS stated that in Australia, the air valves to brakes are also locked out on
machine for further eliminate stored energy causing machine movement.
Al Furness talked
about problems they were having complying with safety standards to install
guarding where needed but at the same time being able to provide adequate
Pete Miller from
P&H asked about having an outside resource come in and do audits for IEEE
standards. This would help with maintaining proper clearances and required
PPE for working around electrical equipment.
Tom Claytor-GE- is
thinking that opening air breakers will eventually require operator to wear
Nomex clothing and have a standby person there for rescue.
Al Furness talked
about an incident at Colowyo where a breaker blew up due to dirt. It was
determined that proper maintenance of the breaker would have prevented the
Craig Russell –
Decker- discussed purchasing buying cheaper devices that what was ordered to
save money and the need for electrical personnel to verify items purchased are
Tom Claytor –GE-
talked about a video produced by Gould showing breakers failing. Felt it
would be something all should see.
discussed the possibility of older properties not having systems electrically
safe due to expansion of the years. Breaker interrupting rating…etc.
New technology and innovations:
talked about the plc upgrade they did for a 2300 machine. Went very well and
they are seeing increased productivity gains due to field control.
–Cordero- stated that they have started installing led’s in place of
incandescents in those areas that are hard to access. There are additional
costs up front but eliminates frequents re-lamping.
stated that Jon Tucker-Alcoa- has used wire technology to gather information
from machines to the office.
Rojo- talked about the WBM (boom monitoring) system they have on their
draglines. Gives instant feedback to operators and has lowered boom repairs.
–Cordero Rojo- talked about remote camera uplinks on draglines. Don Paterson-DCS-
stated that John Tucker –Alcoa- does this also.
Rick Scherer of KEC
shared two incidents that happened at KEC.
1. Wire rope
was being removed from the spool when a bystanders finger was smashed as a
result of the rope coming lose and not being wound in a “typical” method.
2. A contracted
cleaner was nearly crushed when he was trapped between a closing door on a
vacuum truck. This involved two people that where either new or working on a new
Rick from Black
Thunder talked about the fall prevention program that Thunder is currently
undergoing. This program was similar to those that had been presented at groups
John Barrant from
P&H talked about improvements in P&H control systems to resolve issues when the
reference signal is lost. He reviewed that without a reference signal to break
the bucket will coast for quite some time. This is currently being tested and
will be released to the public after testing.
Rick Scherer – KEC-
Rick asked the group for feedback concerning Rio Tinto’s (KEC’s parent company)
safety standard to limit access to MCCs and switch gear. Several comments where
made about concerns with the NEC and negative safety implications from this.
Mark – Helwig –
Noted that Helwig has new covers available for most all applications that do not
have bolts or other parts that could be dropped into rotating apparatus
Commutator mentioned that they are currently use 125 or 150 percent of rated
speed as the standard for testing based on motor size. While this was available
before it was as a special requests.
John – P&H – is
currently developing new operator assist technology.
Mark – Helwig – Mark
mentioned that he as well as Helwig is committed to understanding and finding a
resolution to the cold weather stripping issues seen by many users in the PRB.
Rick – Thunder Basin
Coal – 8750 soft start utilized in South American ARC mine would be a good
solution to coal weather issues with bearing wiping. Rick Scherer noted the
presentation (to be presented at this meeting) by KEC on their soft start system
and effects on bearing life would need to be measured.
presentations we would like to see:
Impact on limits and
control systems due to P and H move to standardize control systems and hardware.
MSHA forum at the
next Denver meeting.
KEC handheld data
collection and impact on maintenance programs.
breakout separated by equipment and manufacture. IE PH shoves, BE draglines.
purchased a simulator, They use this for there trucks ,and plan on. other
At Coteau they have
safe start program, they use tapes to make everyone more aware.
Kennecott is using a
Takes 5 program to make them more aware and Gary Sorensen did the Takes 5 said
it was good but time consuming. It does help New Employees be more aware of
Motor running well
all of sudden began dusting brushes. Tried lots of different things, brushes,
further research changed out an air compressor the vent
B.I has a new Midas
program used with visual aides to store data for investigation .
STARTCO has some new
software for ground fault system, you may check with them for more information.
Falkirk mine is
using radio control from some pump systems
Future of Mining
-Wyoming mining Associated
Mercury Issues and
and. unified system.’ Can we set. a standard and who sets it.?”
Jerry Endres from
TXU spoke of efforts to get MSHA approval for defeating the ground monitor
circuit in the substation feeding a dragline during boom lowering and raising
The concern is that
the ground monitor may trip during the process causing the boom to be damaged.
His mine has
petitioned MSHA for a variance to allow them to defeat this protection function
during the process, and expects it to be approved by MSHA soon.
Rob Marnell from
DCS discussed the changing requirements for vendors to work on customer mine
sites. Job Hazard Analysis forms are required before beginning work which
outline the task to be completed, the hazards involved with the tasks, and the
specific steps to be taken to minimize the exposure to these hazards.
Some mine sites are
requiring vendors to perform the electrical inspections on their hand tools
before entering the mine site. The mine has performed this service in the past,
but is no requiring the vendor to conduct their own inspections. This means the
vendors will be required to have a MSHA qualified electrician conduct this test.
Some vendors already
have this electrical qualification, Steve Baade and Rob Marnell, both vendors,
indicated that they have the MSHA qualification.
Doug Grendahl from
Kennecott Energy added that there is an issue with HVAC service personnel. If a
unit is to be serviced in the shop or office facility, no MSHA qualification is
required. However, if a unit on a dragline or shovel is to be serviced, the
qualification will be necessary, or the service person will have to work under
the direct supervision of a qualified electrician.
Also, permission to
deviate from the requirement to have the vendor, not the mine electricians
perform the hand tool tests will have to come from the mine manager.
John Ozaltin from
Carbone offered to make a presentation on new technology in carbon brush and
brush holder technology. He also has information on a hot change procedure for
changing brushes on operation equipment.
Steve Baade from GE
discussed the changing nature of the joint venture with Toshiba. The Toshiba
side of the group is becoming the project integrator, allowing a wider range of
third party equipment to be applied to new machines. For instance, an Allen
Bradley PLC is being applied on a new dragline installation instead of a GE
unit. The system integrator can choose from six different transformer
manufacturers for isolation transformers. They are no longer tied to GE only
Roger Lorenz from
Argo Discussed the storage of electrical components on warehouse shelves. He has
found that some customers are receiving electronic component cards and removing
them from their static protective wrapping before putting them on the warehouse
shelves. He would like everyone to remember that the anti static wrapping should
stay on the items until they are placed in service.
He also discussed a
new program to take over 100% of the customer inventory of spare electronic
parts, and maintain them through the Argo operation. This will include on site
parts storage, and the ability to ship from an Argo warehouse location, or even
drop shipping from a manufacturers facility. The parts can be shipped by
Ken McCarthy from
Kiewit Mining Group thought a presentation on the top 20 MSHA citations would be
interesting. This might give us an opportunity to share with each other what
MSHA inspectors are looking for.
Jerry Endres from
TXU spoke of a citation he received on a control power transformer. The unit was
not fused on the primary, and only on one leg of the secondary. This is the
configuration of the equipment as it was originally designed and shipped by the
manufacturer. Jerry felt that his mine site was at risk because there are
numerous installations of this type on his site.
Doug Grendahl spoke
of an MSHA inspector who found a damaged drop cord in the shop facility with a
do not operate tag attached. The inspector was not satisfied with this level of
tag out and suggested the plug be cut from the cord, or a lock out device be
used to cover the plug to ensure it is not used before it is repaired. The tag
was not sufficient in the inspectors opinion. Doug ordered some lock out devices
to fulfill the requirement.
Mike Maliske from
Coteau discussed an S+S violation his mine site received for a damaged trail
cable jacket. Jerry Endres from TXU also has been cited for trail cable jacket
damage. (not an S+S violation)
Jerry Endres from
TXU discussed the increased level of electrical inspections. Some inspectors are
approaching the mine electricians to ask them to demonstrate how substation
protective relay settings are being determined, or what the ampacity of a given
piece of trail cable is. He felt this is an increased level of inspection asking
for engineering data.
Jeffery Duncan from
Coteau spoke of MSHA inspectors requiring more information be kept on the
maintenance and repair of circuit breakers.
Ken McCarthy from
Kiewit Mining Group discussed a recent comment by MSHA that working under the
dragline boom is considered working under a suspended load. This would include
dozer work, and ground man activities. It was suggested that it may be that no
work within the dragline radius of operation could be performed.
Ken also discussed
work being performed on a dragline boom and mast in the lowered position. What
suspended load consideration will MSHA be looking at. There is an MSHA letter
out regarding dragline boom work in the lowered position.
Vivian Fadlevich of
Consolidated Mine Service spoke of working to power wash dragline booms and
masts in the raised and lowered positions and the hazards and regulations
Steve Baade from GE
spoke of some of the innovations on the new BNI dragline he recently visited in
North Dakota. They are currently working on the revolving frame, the MG sets are
on the machine, the motors are still in protected storage, swing case boring is
being done, operator cab not yet mounted, electrical cable about 50 percent
complete, the house is not yet complete.
The machine is
scheduled to walk off the pad October 1. The machine is being built in a fashion
to be able to expand it from a 4 hoist, 4 drag, 4 swing motor machine to a 5
hoist, 5 drag, and 6 swing motor configuration if the customers digging
conditions change in the future. (Cool)
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