Down the Rabbit Hole with Graeme Hill

From down below and up above— Industry expert, Graeme Hill reveals the power of complex lifting systems

With a career spanning passenger lifts, forklift manufacturing, container handlers, and theatre hoisting systems, Graeme Hill has established himself as a specialist in designing tailored lifting solutions. 

Based in WGA’s Newcastle office, Graeme is a Principal Mechanical Engineer and one of Australia’s rare experts, with over 30 years of experience in mechanical design. His specific expertise in mine winders plays a crucial role in maintaining safety standards and ensuring compliance across Australia’s top coal-mining state, New South Wales (NSW).

Imagine entering a lift with 150 people, preparing to descend a thousand meters underground; a thought flickers through your mind – ‘Can this lift really hold all of us?’

The answer lies within the marvels of engineering, where ingenuity and rigorous safety regulations blend. 

Designing and maintaining winders demands close collaboration between mechanical, structural, civil, electrical, and functional safety engineers. At WGA, our strong inter-office partnerships allow us to unite these disciplines, ensuring every project benefits from truly cross-disciplinary expertise.  

Let’s dive down the rabbit hole…

WHAT IS A MINE WINDING SYSTEM? A mine winder is a type of hoist specifically designed for the mining industry. It’s like an oversized passenger lift. They can carry up to 150 personnel or equipment and then descend to depths of over 1200 metres underground!

A powered winding installation is a specialised hoisting system used to transport personnel or bulk materials to-and-from deep underground locations. They can service vertical mine shafts or horizontally sloped “drifts” and can travel more than 1200 metres underground at twice the speed of the fastest passenger lifts Illustration: Double Drum Vertical Shaft Winder including Balance Ropes. Source: NSW Resources Regulator Technical Reference Guide

Mine winders are considered High-Risk Plants and Principal Mining Hazards, and so their designs are subject to strict technical standards and regulatory compliance orders.

There are a variety of different types of mine winders, including: vertical shaft winders, drift winders, friction (Koepe) winders, direct-haul, Blair winders, shaft-sinking, and single and double-drum. The type of winder used will depend on the needs of the operation.

A HIGHLY REGULATED SYSTEM

The design, inspection, auditing, maintenance and operation of mine winding systems is heavily regulated in New South Wales.

Any new winder or any modifications made to the design of a powered winding system, needs to be formally reviewed by an independent third-party engineer with experience in winding systems.

New South Wales has some of the most active mines in the country, and the most stringent regulations, and in many ways is ahead of the world when it comes to the regulation of powered winding systems as high-risk plant in mines. The Resources Regulator, a State Government body within NSW Resources that looks after mines and mining operations, mandates five-yearly safety audits and a strict design-registration process, placing the state at the forefront of mine winder safety globally.

“Even if it was not mandated, there’s a lot at stake—these systems work extremely hard and carry people; therefore, safety is paramount.”—Hill

While some Australian states adopt more rigorous standards than others, Hill notes that tier–one companies, seek additional independent verification to ensure compliance with best practices. Hill adds, “a lot of the manufacturers are also voluntarily exceeding the requirements of those standards because they understand the safety criticality of their equipment.”  

DID YOU KNOW?

The Port of Newcastle in the state of New South Wales is home to the world’s largest coal export. Located on the east coast, it is a major producer of coal, gold and copper, supporting the jobs of over 40,000 people in NSW, according to the Australasian Institute of Mining and Metallurgy.

From the depths of mineshafts to the heights of theatre stages – advanced lifting systems keep things moving safely and spectacularly. 

Hill’s expertise is not limited to the mining industry. He also has a passion for theatre hoisting and lifting systems with a portfolio spanning the Sydney Opera House, Art Centre Melbourne’s Hamer Hall, Perth’s Heath Ledger Theatre, Queensland Performing Arts Centre, school theatres, and television studios, including Channel 7 and ABC Studios.   

“Theatre hoists and mine winders share many core components, but the safety requirements and operational environments differ,” explains Graeme.

Standing under a suspended load at an industrial site can result in an instant ban from that site. However, in theatres, performers on stage do this all day, every day, and without a second thought. The reason they can rest assured is the engineering rigour that goes on behind the scenes (pun intended).

Unless you’ve been backstage, you would not believe the extent, variety and complexity of the machinery that is hoisting: lighting bars, scenery lines, speakers, props, acoustic panels, as well as the flying (i.e. the aerial suspension) of the performers themselves.

Safety goes beyond just design, as an appropriate and practical maintenance regime it is also necessary to ensure the continued safety of personnel. 

Experience the Difference in Lifting Projects

Recognised for its technical proficiency and extensive experience in delivering independent and impartial design audits and inspections, WGA has earned a distinguished reputation within the lifting and hoisting industry.

WGA has a proud history in hoisting all manner of things, from shiplifts to the world’s most renowned theatres. The cross-industry experience brings a unique perspective to innovate and improve.

“We’ve got a lot of good people to call upon, with decades of experience. And with WGA, the person you speak to is the person doing the work. So, if you need help with a winder, you can call me,” says Hill.

Graeme’s recent work includes a major winder upgrade at Metropolitan Mine in NSW – encompassing mechanical, electrical and structural modifications, notably a complete winding-engine replacement. He’s also led reviews of maintenance practices for high profile clients such as the Sydney Opera House and Hutchinson Ports, helping streamline operations without compromising safety.

His passion for engineering is truly unmistakable “For a mechanical engineer who likes stuff that moves, this is pretty cool,” he laughs.

“I’ve worked on lifts that go deeper underground than the height of the Burj Khalifa in Dubai. The only difference is that it’s going down instead of up!” quips Hill.

Watch the highlights here!