Open Cut

Performance of Dragline Revolving Frame and Tub Structures at 125% RSL

Open Cut » Maintenance & Equipment

Published: February 08Project Number: C15043

Get ReportAuthor: Daya Dayawansa, Tony Carpinteri, Henry Bartosiewicz | MTI, Monash University

With mine operators moving to re-rate their draglines to 125% RSL, any structural problems are likely to be exagerated and need investigation. This project sought to evaluate higher loads on the dragline revolving frame and tub structure and develop responsive structural improvements and repair strategies.  This project was undertaken with the following objectives:

  • Develop a clear understanding of the reasons for the past failures
  • Critically review the current repair and modification strategies and methods
  • Evaluate the influence of higher loading (e.g. 125%RSL) on the revolving frame and tub structures
  • Identify possible upgrades (where necessary) and improved repair methods
  • Develop engineering drawings for identified upgrades.  

The investigation was based on two BE1370 machines and two Marion 8050 machines. Inspection of the four machines indicated that comparatively the Marion revolving frame structures perform better from fatigue point of view.  Therefore, it was decided that the instrumentation and measurement and the finite element (FE) analysis should be based on a BE1370 machine.   

The drawings of the selected revolving frame were obtained from Bucyrus and an accurate FE model of the revolving frame structure was generated.  The structure was analysed for 100%RSL and 125% RSL load combinations within this FE model.   The results of the analysis, maintenance records collected from the sites and the observations from the inspections were used to identify the critical areas of the structure.  These observations helped to identify the locations for instrumentation.

The results of the FE model could be calibrated using the measured results.  The remaining component of the investigation was undertaken using the FE model.  The influence of various load combinations at 100% RSL and 125% RSL were investigated to study the influence of 125% RSL loading on the revolving frame structure.   

Two areas which are most critical in the BE1370 revolving structure were identified as the mast anchor area and the centre pin area.  Both these areas carry concentrated loading and hence are important from a structural point of view.  Due to the same concentrated loading, the welded connections in this area tend to generate high stress concentrations that can create fatigue issues.  

Finite element sub-models were created for the two areas and different modification options were studied to increase strength and reduce fatigue.    

The following conclusions have been made from the investigation:

  • It was found that the general total stress levels increased by approximately 12% when the machine is working at 125% RSL compared to 100% RSL.   
  • The critical areas in the structure for strength as well as fatigue were identified using the results of the FE analysis.  The stress ranges for fatigue at these locations were also investigated for 100% RSL and 125% RSL.  This analysis indicated that the stress ranges at the critical locations increased approximately by 28% for 12% RSL compared to 100% RSL.  
  • According to this assessment the fatigue damage accumulation at these locations is likely to double when working at 125% RSL compared to working at 100%RSL.
  • The area where the mast anchors are located is the most deficient area of the structure for 125% RSL loading.  This area in some BE1370 draglines has had fatigue issues even before the loading levels of the draglines were increased to 125% RSL.   The measured and calculated general stresses (i.e. not stress concentrations) in the area of mast anchor show that the structure can be considered marginal for strength at 125% RSL loading.  The stress levels in the area are certainly too high to give reasonable fatigue performance.
  • Apart from the area discussed above, the remaining structure is satisfactory for strength.   There are several other areas which can be considered as deficient from fatigue point of view.
  • The mast anchor area and the centre pin area were selected for detailed review and design of structural improvements.  The engineering drawings for the recommended modifications are provided in the report as appendices A and B.  
  • An overall strategy for maintenance of revolving frames and tubs have been developed and presented in section 8 of the final report.


Health and safety, productivity and environment initiatives.

Recently Completed Projects

C28026Measuring The Height Of Fracturing Above Extracted Longwall Panels To Improve Reliability Of Groundwater Impact Predictions

Longwall mining is a mining method widely used in the Australian und...

C25059Development Of An Intrinsically Safe, Integrated Wireless Communications Network With A Distributed Array Of Geotechnical Sensors

For over 20 years, SCT Operations (SCT) have provided a range of ind...

C26051An On-Machine Bolting And Geotechnical Monitoring System

The primary objective of this project was to investigate how laser s...


Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

C29003Wear Debris Removal From Dragline Commutators

The original aim of this project was to establish a method of removi...

C28037Local Scale Dispersion Modelling To Support ACARP Emission Factors

There remains significant concern in the industry regarding the accu...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27032Coal Grain Analysis Applications Handbook

This Handbook sets out recommended practices for using coal grain an...

C26012Improved Flotation Recovery Via Controlling Froth Behaviour

There is no real-time measurement for coal flotation performance, ma...

C27012Towards Better Fine Coal Classification

It is well recognised that the efficient classification of fine coal...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

C27008Selective Absorption Of Methane By Ionic Liquids

The connection of a ventilation air methane (VAM) abatement plant di...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community


National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook