Manufacturing, Engineering and Technology Fabrication and Extraction

Winder Operation And Control Programme Training

SAQA US 110153 | NQF 3 | Credits 19 | Duration 16 Days
From $2,765 per delegate

Description

This programme equips learners with the theoretical knowledge and practical skills required to safely and efficiently operate and control winder systems in a mining or industrial environment. Learners will gain competence in starting, monitoring, and stopping winder operations while adhering to safety regulations and standard operating procedures.

Learning Outcomes

  • Apply relevant safety regulations and procedures to ensure safe winder operation.
  • Demonstrate the ability to start, operate, and stop a winder system under normal and emergency conditions.
  • Monitor winder performance and control systems to maintain optimal operation.
  • Analyze winder faults and implement corrective actions within scope of authority.
  • Evaluate winder operational data to ensure compliance with performance standards.
  • Implement communication protocols and record-keeping procedures for winder operations.

Target Audience

This course is designed for winding engine drivers, operators, and supervisors responsible for the operation and control of winders in mining or industrial settings.

Prerequisites

Learners must be employed in a mining or industrial environment and have access to a winder system for practical assessment.

Course Outline

Day 1: Introduction to Winder Systems and Safety

Objectives:
• Understand the role of winders in mining operations
• Identify key components of a winder system
• Recognise safety protocols and statutory requirements
• Explain the importance of safe winder operation
• Describe the basic principles of hoisting

Topics:
• Overview of mine winder systems
• Types of winders: drum, friction, and Blair winders
• Main components: headgear, sheaves, ropes, conveyances
• Safety legislation: MHSA, SANS, and mine codes
• Personal protective equipment (PPE) and lock-out/tag-out
• Roles and responsibilities of the winder operator
• Basic hoisting cycle

Day 2: Winder Mechanics and Drive Systems

Objectives:
• Explain mechanical principles of winder operation
• Differentiate between AC and DC drive systems
• Describe braking systems and their functions
• Identify rope arrangements and attachments
• Understand the role of the control system

Topics:
• Mechanical power transmission
• Electric motors: AC induction vs DC shunt
• Drive control: variable frequency drives and thyristor controls
• Braking systems: disc, drum, and emergency brakes
• Rope construction, lay, and termination
• Head sheaves and deflection sheaves
• Conveyance attachments: detaching hooks, safety catches

Day 3: Winder Control Systems and Instrumentation

Objectives:
• Describe the control loop for winder operation
• Identify sensors and transducers used in winders
• Explain the function of programmable logic controllers (PLCs)
• Interpret basic control panel indicators
• Understand speed and depth monitoring

Topics:
• Control system architecture
• Sensors: speed, depth, load, tension
• PLCs and SCADA in winder control
• Operator interface: displays and alarms
• Depth measurement: pulse encoders, tachogenerators
• Over-speed and over-wind protection
• Emergency stop circuits

Day 4: Pre-Operational Checks and Inspection

Objectives:
• Perform systematic pre-start inspections
• Check mechanical, electrical, and hydraulic systems
• Verify safety devices and alarms
• Complete pre-operational checklists
• Identify defects and report abnormalities

Topics:
• Daily inspection routines
• Mechanical checks: ropes, sheaves, brakes
• Electrical checks: motor, controls, emergency stops
• Hydraulic/pneumatic system checks
• Safety device testing: slack rope, over-speed
• Logbook entries and defect reporting
• Permit-to-operate procedures

Day 5: Starting, Stopping, and Normal Operation

Objectives:
• Execute safe start-up procedures
• Operate winder under normal conditions
• Monitor instruments and respond to indications
• Perform smooth acceleration and deceleration
• Execute normal stop and park procedures

Topics:
• Start-up sequence: power-up, system checks, clearance
• Joystick and master controller operation
• Acceleration/deceleration curves
• Speed control in manual and automatic modes
• Depth and position monitoring
• Normal stopping procedures
• Parking and securing the winder

Day 6: Man Winders and Personnel Transport

Objectives:
• Understand man winder regulations and safety
• Operate winder for personnel transport
• Manage boarding and alighting procedures
• Apply speed restrictions for man winding
• Respond to passenger communication signals

Topics:
• Man winder regulations: MHSA Chapter 8
• Pre-trip inspections for personnel conveyances
• Speed limits and smooth ride requirements
• Signalling systems: bell codes, radios
• Emergency procedures for man winding
• Overcrowding prevention
• Communication with onsetters and banksmen

Day 7: Rock Winding and Material Handling

Objectives:
• Operate winder for rock and material transport
• Manage skip loading and dumping cycles
• Monitor load indicators and prevent overload
• Coordinate with loading stations
• Optimise cycle times safely

Topics:
• Skip types: bottom-dump, side-dump, cross-over
• Loading and dumping sequences
• Load monitoring: weight cells, power draw
• Overload protection systems
• Cycle optimisation: acceleration, speed, deceleration
• Conveyance change-over procedures
• Handling ore and waste rock

Day 8: Emergency Procedures and Fault Response

Objectives:
• Identify emergency situations in winder operation
• Execute emergency stop procedures
• Respond to power failures and rope slips
• Manage stuck conveyances
• Conduct post-emergency inspections

Topics:
• Emergency stop: manual and automatic
• Power failure: backup systems and brake application
• Rope slip detection and response
• Conveyance stuck in shaft: recovery methods
• Fire in winder room: extinguisher use
• First aid and rescue coordination
• Incident reporting and investigation

Day 9: Brake System Testing and Adjustment

Objectives:
• Understand brake performance criteria
• Perform brake system tests
• Adjust brake clearances and pressures
• Interpret brake test results
• Document brake test records

Topics:
• Brake types: service, emergency, parking
• Brake test procedures: static, dynamic, torque
• Brake clearance adjustment
• Hydraulic pressure settings
• Brake wear monitoring
• Testing intervals and legal requirements
• Recording and reporting brake tests

Day 10: Rope Inspection and Maintenance

Objectives:
• Inspect winding ropes for defects
• Measure rope diameter and elongation
• Identify discard criteria
• Understand rope lubrication and maintenance
• Maintain rope records

Topics:
• Rope inspection methods: visual, magnetic, ultrasonic
• Defect types: broken wires, wear, corrosion
• Diameter measurement and discard limits
• Elongation and lay length checks
• Rope lubrication: types and application
• Capel and socket inspection
• Rope replacement and splicing basics

Day 11: Conveyance Maintenance and Safety Devices

Objectives:
• Inspect skips and cages for defects
• Test safety catches and detaching hooks
• Maintain guide systems and shaft furniture
• Understand conveyance change-out procedures
• Ensure safe conveyance operation

Topics:
• Skip and cage inspection points
• Safety catches: function and testing
• Detaching hooks: operation and maintenance
• Guide rails and bunton clearance
• Shaft furniture: signals, gates, lights
• Conveyance change-out: planning and execution
• Load testing and certification

Day 12: Control System Diagnostics and Troubleshooting

Objectives:
• Diagnose common control system faults
• Use PLC diagnostic tools
• Interpret alarm logs and fault codes
• Troubleshoot sensor and actuator issues
• Perform basic repairs and adjustments

Topics:
• Fault finding methodology
• PLC diagnostics: ladder logic, status lights
• Alarm history and trend analysis
• Sensor troubleshooting: speed, depth, load
• Actuator issues: valves, drives
• Communication faults: network, fieldbus
• Component replacement procedures

Day 13: Winder Performance Optimisation

Objectives:
• Analyse winder performance data
• Optimise speed and acceleration profiles
• Balance load distribution
• Reduce energy consumption
• Improve cycle time without compromising safety

Topics:
• Performance metrics: cycle time, payload, utilisation
• Speed profile optimisation
• Acceleration and jerk control
• Load balancing in multi-level shafts
• Energy efficiency: regenerative braking
• Data logging and performance reports
• Continuous improvement techniques

Day 14: Shift Handover and Communication

Objectives:
• Conduct effective shift handovers
• Communicate clearly with shaft crews
• Use standard radio and bell codes
• Document operational issues
• Foster a safety culture through communication

Topics:
• Shift handover procedures: verbal, logbook
• Communication protocols: radio, telephone, signals
• Bell codes and their meanings
• Reporting defects and incidents
• Team coordination: onsetters, banksmen, maintenance
• Safety meetings and toolbox talks
• Conflict resolution in the control room

Day 15: Integrated Operations and Scenario Training

Objectives:
• Apply all skills in integrated scenarios
• Manage multiple conveyances and levels
• Respond to combined normal and emergency situations
• Demonstrate situational awareness
• Coordinate with multiple shaft stations

Topics:
• Multi-conveyance operation
• Simultaneous man and rock winding
• Emergency scenario: power loss with personnel in shaft
• Breakdown scenario: rope slip with skip loaded
• High traffic period management
• Decision-making under pressure
• Debrief and lessons learned

Day 16: Assessment and Certification Preparation

Objectives:
• Prepare for final knowledge and practical assessments
• Review key learning outcomes
• Complete written test
• Demonstrate practical competence
• Understand certification requirements

Topics:
• Course review: theory and practical highlights
• Written assessment preparation
• Practical assessment: pre-start, normal operation, emergency
• Assessment criteria and pass marks
• Certification process: SAQA credits, mine certification
• Career progression opportunities
• Course evaluation and feedback

Practicals

64 hours of practicals To be conducted online or on-campus or in-house
Overview

The practicals provide hands-on experience on a full-scale winder simulator and actual winder equipment under supervision. Learners apply pre-start checks, normal operation, emergency procedures, and maintenance tasks to build competence and confidence in real-world scenarios.

Practical Activities
  • Pre-Operational Checks and Start-Up — Learners perform systematic pre-start inspections on a winder simulator and actual winder, then execute correct start-up procedures. (12h)
  • Normal Operation and Man/Rock Winding — Learners operate the winder for both personnel and material transport, managing speed, depth, and communication with shaft crews. (20h)
  • Emergency Procedures and Fault Response — Learners respond to simulated emergencies including power failure, rope slip, stuck conveyances, and fire, using correct protocols. (16h)
  • Brake Testing and Rope Inspection — Learners perform brake system tests and rope inspections on actual equipment, recording results and adjusting as needed. (10h)
  • Integrated Scenario and Assessment — Learners demonstrate integrated skills in a comprehensive scenario combining normal operation and emergencies, followed by practical assessment. (6h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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