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Application of TCK.W Wire Rope Online Non-destructive Testing Technology

(Yungang Coal Mine, Datong Mining Industry Group, Datong Shanxi Province 037017)

Abstract: This paper analyzes the importance and safety of wire rope testing in mine hoisting system, and summarizes the application of TCK.W wire rope online nondestructive testing technology.

Keywords: hoist; wire rope; online monitor

Chinese library classification number:TD532

Document Code:A

Article Number:1003.773X(2015)07.0080.02

DOI:10.16525/j.cnki.cn14.1134/th.2015.07.031

Introduction

Hoisting wire rope is the key part of mining hoisting system, which connects the hoisting vessel and winch. The correct operation and timely maintenance is the essential to ensure the safety of mining hoisting operation, extend service life of wire rope and economical operation.

According the National Coal Mining Safety Regulation, hoisting wire rope should be daily checked. In the past production activities, wire rope daily check mainly depends on manually checking, by means of hand touch, knock inspection, calipering. During inspection, two workers cooperate together; one person is at the mouth of the well, the other person is at the outlet of the winch room, each is responsible for an appointed wire rope. Only approved experienced technical personnel can perform this task. TCK.W wire rope online inspection technology can effectively make up for the deficiency of manual detection, inspect running status of wire rope in real time, greatly improving labor efficiency, and provide accurate assurance to prevent wire

rope breaking.

1. Disadvantages of Manual Detection

Checking the wire rope in service is an effective way to timely discover its defects and to know the degree of strength loss. Daily check mainly comprises, broken wire, rope diameter deformation, rope lubrication and corrosion, rope end and rope clip connection (the elongation change of the whole rope length). Manual detection still consists of the existing three problems:

1) Long idle running time and high energy consumption.

Manual detection method, through the control of low-frequency electronic control to run the winch at a speed of about 0.3m/s, detects the wire rope by the means of visual inspection, hand touch, knocking method. If encountering suspicious defect section, stop the equipment immediately and use caliper to measure. If the wire rope is covered by heavy grease, the inspection would take longer time because of cleaning. Take Yungang mine of Datong coal mine group as an example, the main motor power of the winch is 800kw, and its total length of wire rope is 200m; According to the requirements of the regulations, the wire rope should be inspected once a day, and each inspection of the wire rope takes about 40min. The annual inspection of this wire rope consumes about 192,000 kwh electric energy. The average unit price of electricity is 0.72 RMB/KWH, so the annual expense for wire rope inspection is about 138,200 RMB.

2) Insufficient qualitative identification of inspection data, and potential risks cannot be fundamentally eliminated.

Manual detection can only detect the external changes and damages of wire rope, which is limited to skilled workers with rich experience. While, the internal broken wire, abrasion, corrosion, especially fatigue, are barely detected by manual detection, which become a hidden danger.

Once the rope is broken, the accident would inevitably lead to great disaster, such as equipment damage, facilities repair, production halt and rectification. The direct losses are tens of millions RMB; In case of casualties, the direct harm to the victims' families and the negative influence of the coal mine cannot be measured and compensated through economic means.

3) Long manual maintenance time reduces the production efficiency.

Manual inspection is inefficient and wastes a lot of production time. Take Yungang mine for an example, the average hoisting speed is 7.8 m/s, a cycle time of hoisting is about 3 min, the hoisting quantity raw coal is 9 ton X 4 = 36 ton during one cycle. According to the requirement of regulation, daily check of wire rope takes 40 minutes, which corresponds roughly to 13.33 hoisting cycles, and equivalents to the hoisting raw coal quantity is 479.8 ton. At present, the unit price of coal with 5500 kcal calorific value is 475 RMB/ton. Thus, the wire rope inspection costs 228,000 RMB loss every day.

2. Development and Application of wire rope NDT technology

The non-destructive testing technology of wire rope is developing continuously with production demand and scientific plus technological progress. In the 1960s and 1970s, the western industrial countries, mainly the United States, created a non-destructive testing technology of wire rope using the "hall effect" supplemented by permanent magnet excitation. Due to the detection equipment with a strong magnet, it is described as the industry "strong magnetic detection technology." The technology can detect the external magnetic flux leakage information close to the wire rope and a low amplitude measured, but the internal magnetic flux information of wire rope is lacking. Besides, the products have low scientific and technological content and poor practical performance. Limited to laboratory research, it has been gradually eliminated by the market since this century.

In the 1980s and 1990s, a technique of nondestructive testing of wire ropes with magnetic remanence was developed with the help of highly sensitive sensors. This technique as compared with "strong magnetic detection technology" is able to detect much weaker magnetic characteristic information, and detecting technology, and is in opposition to "strong magnetic detection technology", so it is called "weak magnetic detecting technology". This technology can capture the wire rope of magnetic flux leakage and magnetic flux information, enrich the wire rope nondestructive flaw detection methods, to rewrite the history of magnetic nondestructive testing of wire rope inspection.

TCK.W wire rope inspection device utilizes weak magnetic detection technology, consisting of highly sensitivity sensor, and combines the application of components of “Dou digital integrated technology”. Thus, this inspection device can not only accurately detect the quantitative detection of internal and external wire rope defects, but also correctly evaluate of the service life of the wire rope, but also reports real-time test results in computer.

Through verification of actual field application and usage, TCK.W inspection device can visually and clearly detect the degree of wire rope damage, and can accurately and objectively evaluate the load bearing capacity of wire rope, to meet the requirement of quantitative management of wire rope safety in coal mines. Other features such as lighter and simpler device operation are more conducive to the popular use in coal mine.

3. Workflow of TCK.W wire rope online monitoring system

TCK.W fixed inspection device when mounted in the key section of the wire rope for monitoring, will complete automatic detection during the normal working process of wire rope. The basic workflow includes:

TCK.W weak magnetizer magnetizes the wire rope first, and then using high sensitive inspection device to capture the entire status information of wire rope, and outputs the original detection signal.

After receiving the original detection information, the TCK.W intelligent data collection and conversion workstation preliminarily processes and stores the original data, and sends the wire rope damage signal to the main control center in real time through wired or wireless communication transmission.

TCK.W distance encoder mechanically couples with wire rope, according to wire rope running route, generates position information by pulse signal, and the signal is send synchronous with defect signal of wire rope to the main control center.

According to the processing results of the multi-function data collection and conversion workstation, TCK.W automatic control alarm device provides an early-warning light source signal to evaluate the safety state of the wire rope, which is to indicate the damage level of the wire rope: the green light indicates that the wire rope is in a safe state; the yellow light indicates that the defect value of the steel wire rope under test has been within the range of 60 ~ 90 of the safe limits line, indicating that users should pay more attention to it. The red light indicates that the wire rope has been seriously damaged and is in a dangerous state.

TCK.W multi-channel terminal control device, namely the control center, can comprehensively analyze the collected detection information through the program software, provide users with daily analysis and processing results and the change trend of wire rope defects, and display or print out the detection report through the computer terminal. The user can clearly view the safety status of the wire rope from the test report.

4. Conclusion

1) Through frequent application of TCK.W Portable Inspection Device in Yungang mine, it greatly improves the safety detection levels of hoisting wire rope, thoroughly changes the hoisting wire rope inspection done only by the means of manual method. TCK.W portable inspection device can detect both external and internal defects, especially wire rope fatigue, which could effectively prevent accident.

2) TCK.W Wire Rope Online Inspection

Technology can accurately and reasonably evaluate the load bearing capacity, safety coefficient and service life of wire rope, and provide a scientific basis for analyzing rope safeties and reducing the cost of rope use. In terms of management, it also provides reliable technical guarantee for the improvement of safety management in Yungang mine.

3) Application of TCK.W Wire Rope Online Monitoring System brings considerable economic benefits to Yungang mine. There are four winches in total in Yungang Mine. It saves nearly 1,000,000 kW·h electricity energy and reduces shutdown time for inspection about 973h annually. If all this expensed energy and time are used in production, the mine can additionally produce 304,000 ton raw coal, based on the calculation of 5000 ton/day of raw coal lifting per day of 16 hour.

Reference

[1] Safety Regulation in Coal Mine [S], Beijing, Coal Mine Industry Press, 2004.

[2] Huang Buyun, Zhang Dexin, Practical Guide of Wire Rope Inspection, [EM], Beijing, Coal Mine Industry Press, 1993.

[3] Mine Hoisting Wire Rope [M], Beijing, Coal Mine Industry Press, 1979

[4] Zhou Datong, Model Selection, Installation and Maintenance Handbook of Coal Mine Equipment, Beijing, Coal Mine Science and Technology Press, 2010

[5] Fu Quanzhen, Mine Wire Rope Use, Detection and Accident Case Analysis, [M], Beijing, Coal Mine Industry Press, 1999

[6] Lu Qing, Xu Wenshang, Sun Zhihai, Fault Analysis of Mine Hoisting Wire Rope Based on FTA [J], Coal Mine Machinery, 2006, 27(2): 356—358.

Author Introduction

Yang Buzhong (1980-), born in Datong, Shanxi Province, Engineer, granduate from Jiaxing Institute, major in electrical engineering and automatization, works in the department of mechanical and electrical engineering of Yungang mine, Datong coal mine group.

(Editor: Zhang Kehui)


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