International Journal of Mechanical Engineering and Technology ENGINEERING AND INTERNATIONAL JOURNAL OF MECHANICAL (IJMET), ISSN 0976 6340(Print),

, ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 416-421 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com

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IN-SITU NONDESTRUCTIVE ASSESSMENT OF A WINDER ROPE OF A COAL MINE

Dr. Debasish Basak1 and Ms. Bubun Das2 Senior Principal Scientist & Head, 2 Project Assistant Electrical Laboratory, CSIR-Central Institute of Mining and Fuel Research, Barwa Road, Dhanbad-826015, INDIA E-mail: deba65@yahoo.com1, bubun0326@yahoo.com2
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ABSTRACT Nondestructive testing (NDT) devices for inspecting wire ropes have been in use for well over fifty years. The effective technology for these devices depends on the magnetic properties of steel wire rope. Regular NDE inspections provide a powerful tool in monitoring the rate of degradation of a rope. An attempt has been made in this paper to monitor and evaluate the condition of 6X25, RHL, fibre main core (FMC), winder rope of K-4000 Winder of Shaft Mine during three investigations over 13 months at regular intervals. Keywords: winder rope, nondestructive technique. 1. INTRODUCTION Nondestructive testing (NDT), also referred to as nondestructive examination (NDE) and nondestructive inspection (NDI), is a family of specialized technical inspection methods that provide information about the condition of materials and components without destroying them. NDT examines actual production pieces and reveals the presence of flaws, which can be evaluated against accept/reject criteria. It is one of the major tools of quality control. The electromagnetic nondestructive test (NDT) is defined [1] to be any test or measurement method for inspecting or evaluating materials or products which does not adversely affect their serviceability and which use the effects of electromagnetic induction, electromagnetic fields or varying currents for probing, measuring or inspecting. Because the tests are non-destructive, 100% inspection can be made to assure uniform quality of products for critical use. The wide application of nondestructive testing is one of the characteristic features of the scientific and technical revolution at the close of 20th century. Progress in NDT has been provided for strict control on the properties and quality of every part or component, unit and product at every stage of production and exploitation. NDT, however, was quite
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME May August

involved as also expensive. Irrespective of the increasing costs and prices there has been considerable constant growth in NDT application [ [2]. 2. ELECTROMAGNETIC TYPE NONDESTRUCTIVE TESTING INSTRUMENTS In mining and other areas where NDT of metallic ropes are involved, electromagnetic methods are generally used. Nondestructive testing (NDT) devices for inspecting wire ropes have been in use for well over fifty years. The effective technology for these devices depends on the magnetic devices properties of steel wire rope. Wire rope NDT is used extensively in the routine inspection of mine hoist ropes and aerial (track and haulage) ropes throughout the world. The principle of operation for electromagnetic nondestructive evaluation of wire rope nondestructive systems employs [3]: measurements of fringe fields near the surface of the rope to detect local defects such as broken wires, corrosion pitting, local wear. measurements of changes in magnetic flux passing through a short length of rope length to quantify changes in metallic cross section. A modern method of nondestructive test of metallic materials must be objective, rapid, cheap and exact. In addition, it must serve a wide field of application. A rational method of test must evaluate its results and designate the flaw locations automatically. It ate must sort the tested parts and feed the signal pulses into automatic production units and/or statistical counters. X-ray, ultrasonic and magnetic particle inspection is ideally suited for ray, special problems. But they have the disadvantage of relatively slow speed of test, difficult pecial to adapt and very expensive to make them automotive automation and also, the field of application is limited. The instrument used for scanning of winder ropes is of Zawada NDT, Poland make. Instruments operation principle is based on permanent magnet method (also called DC magnetic method) [4-6] originally developed by scientists of the University of ] Mining and Metallurgy (AGH) in Krakow for magnetization of the rope with permanent rope magnets and detection of the changes of magnetic field around the rope and total magnetic flux. A diagram showing the locations of sensors and the detection of various classes of defects in rope has been shown in Fig.1. bee

Fig. 1. Location of sensors and the detection of various classes of defects in rope. n Various types of sensors have been applied. Depending on the design of the magnetic concentrators and type, number and location of sensing devices, sensors provide different signals. Inductive coils and/or Hall generators are popularly used as sensing devices. uctive
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

However generally, from the viewpoint of adaptation in application sensors can be divided into two types: (1) Local Fault (LF) sensors and (2) Loss of Metallic crosssectional Area (LMA) sensors. Broken wire or corrosion pit creates radial magnetic flux leakage and LF sensor detects it as the rope passes through the sensor. LF sensor is placed coaxially around the rope, centrally between magnetic poles of the magnetizing circuit. Its signal is rather qualitative than quantitative. However, this signal provides information about the presence of local fault as also its approximate magnitude. LMA sensor measures total axial magnetic flux in the rope as an absolute magnitude or variations in a steady magnitude of the magnetic field. This signal is proportional to the volume of steel or the change in steel cross-sectional area. It provides information about loss of steel due to missing wire, continuous corrosion or abrasion. LMA sensors are located in various places, almost within magnetizing circuit or nearby it. Detectability of rope defects depends mainly on the sensing head employed but readability of its signals and ease of operation depends mainly on recording/processing instrument. The sensing head brings the running sector of wire rope to the condition close to magnetic saturation and provides signals from its sensors. 3. STUDY OF WIRE ROPES USING NDT Assessment of rope condition either by visual examination or drawing a specimen rope length and subjecting it to destructive evaluation seldom speaks about integrity of the entire rope length in the installation [3, 7]. Further, ropes, which are used on friction winders and aerial ropeway passenger cable car installations, cannot be assessed at any cost, due to non-availability of rope length for destructive investigation. Under these situations, non-destructive investigation is the only means for its evaluation to study the behavior. The main objectives for nondestructive evaluation of steel wire ropes used in mine winders are given as follows: study of the condition of ropes over a period of time at regular interval of three months/six months/one year depending on age, condition of ropes etc. in the installation, assessment of the suitability of ropes by non-destructive evaluation, achievement of the optimum safety, economy and reliability during operation of the ropes in current installations. Degradation under service conditions takes place by reduction in thickness due to various forms of corrosion and erosion, crack initiation and propagation due to various mechanisms like fatigue, creep, creep-fatigue, corrosion-fatigue, stress corrosion, hydrogen damage, temper embrittlement, sensitization in stainless steel, etc. and unacceptable micro structural changes. Nondestructive detection and assessment of deterioration is important for life extension. The most conventional inspection method for wire ropes is the visual inspection in which the experts observe the surface and assess the rope condition empirically. They cannot evaluate the inner failure such as corrosion. However, the visual method produces a possibility for inadequate inspection due to its subjectivity. Practically, it is hard and nearly impossible to review thoroughly a rope covered by lubricant. Additionally, only surface faults of the rope can be detected and this is insufficient to define its condition correctly.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

Visual inspection alone is inadequate to provide a real definition of the rope degradation level, even if the inspection is fulfilled conscientiously. Using electromagnetic method, a rope expert has a possibility to estimate the rope condition. Magnetic nondestructive evaluation method is also being used now-a-days to assess the condition of stranded ropes and full locked coil ropes used in Mine winders (cage and skip winders). Mine winders are designed for installation in the vertical and sloping mine shafts. These are used to transfer the load hoisting vessels with mineral resources and rocks, transportation of men, materials and equipment. These also help in checking up and inspecting the shaft and handing up or changing the hoisting and balance ropes. These winders are fitted with all the required protection devices and interlocks that provide reliable and safe operation of hoisting facilities. They are usually considered the most significant piece of equipment at an underground mine and failure of the mine winder can lead to catastrophic results thus safety and maintenance of mine winders are critical to mines operation. When a mine is closed, it is a standard practice to dissemble and refurbish a mine winder for use in a new mine. 4. INVESTIGATIONAL PROCEDURE The internal and external (inner and outer) inductive sensor coils of the Wirerope Defectograph are used to register the defects characterized by stepwise changes in rope cross-section i.e. broken wires (localized flaws) and the hall effect sensor is used to register the relative variation in loss in metallic cross-sectional area due to distributed flaws like wear, corrosion in longer length and abrasion. All the ropes have been calibrated first with metallic rod of known cross-sectional area of 80 sqmm/20 sqmm before actual scanning of ropes. The rope speed has varied from 0.6 to 1.5 meter/second. CASE STUDY One no.of winding rope of 42 mm dia (nominal), construction 6X25, RHL, fibre main core (FMC), of K-4000 cage Winder of Sudamdih Shaft Mine Project, Bharat Coking Coal Limited,(BCCL) have been subjected to nondestructive investigation for the 1st , 2nd and 3rd time, after its installation, for monitoring their suitability in the installation[8].This non-destructive evaluation on one winder rope has been carried out over 13months at three regular intervals of six months each. Average rope speed during investigation of the winder rope has been 0.80 to 1.2 m/sec. Comparative study of the rope over the three investigations has been carried out and following observations is made (Table 1) Table 1 Observation for Rope in the Winder No.1 Time of investigation after rope installation 1 months 7 months 1 year 1month Flaw Laylength Observed Laylength 304 mm 306 mm 308 mm Diameter Off-tension Observed nom. dia. Laylength dia. (mm) 303 mm 42 mm 42 mm 303 mm 42 mm 42 mm 303 mm 41.3 mm 42 mm

nil nil 1

From the observations, the findings are as follows:

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

1) The relative loss in metallic cross-sectional area compared to a healthy portion of the rope is negligible in all three observations. 2) The number of flaws as observed per 100 meters length of rope ranges froms 0 to 1. Laylengths as measured at random in the investigations have ranged from 7.24d to 7.33d, d being the nominal rope diameter in mm, showing an increase of 0.12 d over 13 months from its off-tension value of 303 mm. 3) The diameter has been reduced by 0.7 mm i.e. 1.67% from its nominal value after 3rd investigation. 4) The rope has been found covered with dust moist etc in each study of the rope. 5) The wire rope length of about 5 (five) meters each from both cappel ends are not subjected to non-destructive evaluation due to infrastructural disadvantage. 5. CONCLUSION Two ends of a winder rope are connected to the two different cages on their roofs for the links by cappelling arrangement. The wire rope lengths of about 4 to 8 meters each from both cappel ends are covered/wound with seizing wires preventing outer layer of ropes from coming out. These lengths are not subjected to nondestructive inspection due to instruments positional disadvantage. It has been experienced through destructive study with the 3 meters sample of ropes from cappel ends that generally there is no broken wire throughout this length from cappel ends. In running ropes, broken wires are observed primarily in sections that move over sheaves, pulleys and winch drums. Localized flaws in the form of broken wires usually concentrate near the points which cross and halt in the pulley whenever the cages stop at boarding-deboarding/loading-unloading stations. Usually, breaks develop in segments of the rope surface that come in direct contact with the sheave. If a rope is not examined properly, it may make the transportation operation unsafe, nonproductive and costly affair. The main faults of the ropes are broken wires and disturbances of rope structure because of rather significant bending load on towers and pulleys. Periodic in-situ measurement of faults in ropes would help to find out effects of various parameters on rope life. All wire ropes wear out eventually, gradually losing work capability throughout its useful life making periodic inspections, lubrication, and tensioning necessary. It is important that the wire surface be sufficiently clean so that the broken wires are visible. The study depicts the present condition of ropes only. The measurements are intended to identify rope wear and other deterioration so that a wire is removed from service before it becomes hazardous to use. The reliability of electromagnetic inspection has made it a universally accepted method for the inspection of wire ropes in mining, in aerial ropeway installations etc. It is advisable to compare readings with a signature trace taken when the rope was new or first installed and then subsequent traces, to assess more accurately any degradation which has developed in the rope at the time of evaluation. 6. ACKNOWLEDGEMENT The authors are thankful to Director, CSIR-CIMFR, Dhanbad, India for his kind permission to publish the paper. The views expressed in the paper are of authors and not of the organization they serve.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME 7. REFERENCES [1] [2] H. L. Libby, Introduction to Electromagnetic Nondestructive Test Methods, WileyInterscience, USA, 1971. A. Skordev, Standard-Technical Basis of the System for Non-destructive Testing, J.M. Farley and R.W. Nichols (eds), Non-destructive Testing, Proceedings of the 4th European Conference, London, UK, 13-17 Sept. 1987, Pergamon Press, Vol. 4, pp 2334-2338 D. Basak, Nondestructive Evaluation of Drive Rope: A Case Study, Nondestructive Testing & Evaluation, Taylor & Francis, UK, Vol. 20, No. 4, Dec. 2005, pp 221-229. K. Zawada, Magnetic NDT of Steel Wire Ropes, NDT.net, August, 1999, Vol. 4, No. 8. Zawada NDT Homepage http://www.zawada.z.pl/. MD120B WIRE ROPE DEFECTOGRAPH, http://www.zawada.ndt.com/ content/products/ ZAWADA/ md120.htm. D. Basak, Periodic Nondestructive Evaluation of Steel Wire Ropes: Its Importance and Practical Relevance, NDT.netThe e-Journal of Nondestructive Testing ISSN: 14354934, June, 2006, Issue Vol. 11, No. 6. CIMFR (erstwhile CMRI) Project Reports on Nondestructive investigation on Steel Wire Ropes, 2009-2011.

[3] [4] [5] [6] [7]

[8] .

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