NDT Inspection Unit for Winder Rope

Theme: Asset Optimization & Predictive maintenance

Expected Pilot Duration - NA

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Challenge Summary

As per best Maintenance practice, Inspection of rope is mandatory for weekly & monthly which we are doing manually. Also it is mandatory to do NDT test of ropes ones in 6 months as per DGMS Rules. Since Manual Inspection and testing of winding ropes is laborious & time consuming due to manual efforts. Also manual inspection can only capture 120 deg of rope area. So Digital solution is required to reduce manual intervention and time for inspection.

Challenge Scenario

A typical manual inspection of a 1300 meters winder rope takes ~3hrs. Further, manual testing methods capture only visual defects but not abrasion and strength of the rope. This method of testing requires excess manpower/man hours, and manual means of inspection is inefficient which in turn increases the operational costs and reduces operational hours of the day in terms of loss of production as well. Also visual inspection may not capture complete information which will then capture only during bi-yearly NDT test and therefore timely action cant be taken.

Profile of the end users

Coal Oven Team

Shop Mechanics - Also known as service technicians, these professionals oversee maintenance, inspections, monitor inventory, assemble mechanical components, and perform repairs in the mine

Procurement Team

Plant Managers - It enables plant managers to take decisions on the maintenance , avoid more damage to rope & replacement of winder ropes on time which will avoid unplanned downtimes.

Solution Requirements

NDT inspection of the In-service winder ropes.

Online rope diameter calculation

Real time rope defects monitoring - strand misplaced, loose protruding wires, waviness, birdcage, rope core broken, deformation of rope along with exact location of defect

Intelligent recommendation system for service & replacements

Estimate the probability of failure/maintenance of the winder ropes

Testing speed of inspection unit: 11.8 m of rope/s (Preferred)

Reducing/Avoiding the unplanned downtime by the installation of Intelligent NDT Inspection Unit.

Installation/Integration: The solution should be easily integrable into the existing hoist used for conveyance, without any major modifications.

Minimal Product Training: As the product is being used by shop floor mechanics, the learning curve they have should be minimal and they should be able to use the product seamlessly.

Expected Outcomes

1. Quantified Metrics & Outcomes:
Operational KPIs/Metrics Current Value Expected Target Value
Man Hours 0.5 hours/Rope winder 10 minutes (Through Automated NDT Inspection Unit)
Visual Inspection Manual, Partly (120 deg), 1hr stoppages of operation Fully (360 deg), Automated, Zero stoppages
Rope Dia Measurement Manual,10 minutes stoppage of operation Online measurement, Zero Stoppages
2. Qualified Outcomes:
Operational KPI/Metrics Current State Expected Target State
3. ESG Impact:
ESG Metric Target State (Expected)

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