ACARP ACARP ACARP ACARP
Open Cut

An Improved System for Dragline Rope Condition Monitoring

Open Cut » Maintenance & Equipment

Published: July 13Project Number: C18031

Get ReportAuthor: Erika Margetson, Adam VanDyck | Bureau Veritas Asset Integrity and Reliability Services

In stage one of this project it was demonstrated that it is feasible to use magnetostrictive transducer technologies to generate ultrasonic energy in wire ropes of up to 77mm in diameter and for this energy to be transmitted through the rope and socketing assembly.  The report on stage one report is provided with the final project report.

 

A MsSR3030R guided wave ultrasonic inspection system was acquired and trialled on laboratory rope samples under tension. It was determined that this system was capable of "seeing" a reflection of ultrasound energy from a defect equivalent to 8% loss of overall cross section of the rope under certain specific conditions as discussed in ยง1.2 of this report.

 

The objective of stage two of the project was to trial the same system on a working 106mm diameter dragline pendant rope assembly. This trial was conducted in parallel with the existing radiographic inspection regime.

 

To facilitate this trial, a test subject was provided by the Rio Tinto Mount Thorley Warkworth Mine (MTW). This was a P&H 9020 Dragline (#103 at MTW). The first experiment was conducted onsite in March 2012 at the mast end of the four mast-to boom pendent ropes.  The tension in the cable was estimated at 37 tonnes when the dragline is in its isolated state.

 

Approximately seven to eight months later, these ropes were retired from service and later sent to the Onesteel Molycop Wire Rope Facility in Newcastle, where the experiment was repeated using two of the same rope ends trialled in March 2012, 3B & 3C at three different tension settings, 750 kN (75 tonnes), 1000 kN (100 tonnes) and 1500kN (150 tonnes). The tension was originally set at 37 tonnes; however no distinguishing features could be seen in the data above the noise. A minimum of 75 tonnes was required to produce data, where distinguishing features could be clearly seen. The region targeted was a section 330 mm from the socket on each cable as this has been shown to be the location where most of the failures occurred [3]. Selected results of these two experiments, at MTW and at Onesteel Molycop, were compared and contrasted.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C34007Evaluating Toxicity Of Different Types Of Respirable Crystalline Silica Particles To Lung Cells And Tissues

Silica dust represents one of the most significant occupational haza...

C29010In-Situ Stress Measurement Using Non-Destructive Techniques (Ndts)

Rock in depth is subjected to stresses due to overlaying burden and ...

C33029Review Longwall Face Ventilation To Mitigate Goaf Gas Emissions Onto Walkways And Tailgate End

As longwall mining increasingly targets deeper coal seams, managing ...

Underground

Open Cut

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

Recently Completed Projects

C35029Renewable Energy As Post-Mining Land Use

In 2020, the Queensland Resources Council (QRC), in partnership with...

C33036Radar Tyre Monitor System

This project focussed on trialling a radar sensing technology design...

C26020Preventing Fatigue Cracking Via Proactive Surface Dressing

Fatigue cracking of plant and equipment presents a significant chall...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C28061Quantitative Based Structural Integrity Evaluations Using Modal Parameters Estimation

This project focused on the development and implementation of a quan...

C34039Development Of A Soft Sensor For Predicting Dense Medium Cyclones Performance

This project details the development of a DMC soft sensor for modell...

C34041A Coal Spiral For The 2020S

The objective of this project is to develop an enhanced coal process...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C35039Impact Of Coal Grain Composition And Macerals Association On Fluidity Development In Australian Coals

The coke quality prediction models use thermoplastic terms as key ex...

C36004Physical And Chemical Structure Characterisation Of Biomass For Biocoke Production

Partial substitution of coking coal with renewable biomass is identi...

C35037Examination Of Contraction Pre And Post Resolidification Using A High Temperature Dilatation Rig

This project examined the contraction of coking coal samples, both p...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C34066Safe Operation Of Catalytic Reactors For The Oxidation Of VAM Operating Under Abnormal Reaction Conditions

The catalyst Pd/TS-1 has shown excellent activity in oxidising venti...

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL)

This third and final stage of this project was the culmination of a ...

C29069Low-Cost Catalyst Materials For Effective VAM Catalytic Oxidation

Application of ventilation air methane (VAM) thermal oxidiser requir...

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

NERDDC

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

NERDDC