CRMS PRESENTATION

RECORDER OLD RAU ELECTRONICS

AMRE

MPONENG MINE

OCTOBER 2011

NEW ELECTRONICS & DISPLAY

NEW ELECTRONICS
1
 ROPE TESTING HISTORY IN SA
CHART RECORDER OLD RAU ELECTRONICS

NEW ELECTRONICS & DISPLAY

NEW ELECTRONICS
2
 NEW TRITON RT MOBILE RTU

3
 CRMS
Continuous Rope Monitoring System

Broken Wire during Unloaded Downwards Movement

Moab Khotsong DP Winder Underlay - Old Rope used up to 2011-04-30
0-500 500-1000 1000-1500 1500-2000 2000-2500 2500-3000 3000-3500 3500-4000 4000-4500 4500-5000 5000-5500 5500-6000 6000-6500 6500-7000 7000-7500 7500-8000 8000-8500

8500
8000
7500
7000
6500
6000
5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0

-2.5
35.5
73.5
111.5
149.5
187.5
225.5
263.5
301.5
339.5
377.5
415.5
453.5
491.5
529.5
567.5
605.5
643.5
681.5
719.5
757.5
795.5
833.5
871.5
909.5
947.5
2011/04/30

985.5
1023.5
1061.5
1099.5
1137.5
1175.5
2011/04/19

1213.5
1251.5
1289.5
1327.5
1365.5
1403.5
2011/04/08

1441.5
1479.5
1517.5
1555.5
1593.5
1631.5
2011/04/07

1669.5
1707.5
1745.5
1783.5
1821.5
1859.5
2011/04/06

1897.5
1935.5
1973.5
2011.5
2049.5
2087.5
2011/04/05

2125.5
2163.5
2201.5
2239.5
2277.5
2315.5
2353.5
2391.5
2429.5
2467.5
Rope Position in Shaft [m]

Broken Wire during Loaded Upwards Movement

Moab Khotsong DP Winder Underlay - Old Rope used up to 2011-04-30
0-500 500-1000 1000-1500 1500-2000 2000-2500 2500-3000 3000-3500 3500-4000 4000-4500 4500-5000 5000-5500 5500-6000 6000-6500 6500-7000 7000-7500 7500-8000 8000-8500

8500
8000
7500
7000
6500
6000
5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
-2.5
35.5
73.5
111.5
149.5
187.5
225.5
263.5
301.5
339.5
377.5
415.5
453.5
491.5
529.5
567.5
605.5
643.5
681.5
719.5
757.5
795.5
833.5
871.5
909.5
947.5
2011/04/30

985.5
1023.5
1061.5
1099.5
1137.5
1175.5
2011/04/19

1213.5
1251.5
1289.5
1327.5
1365.5
1403.5
2011/04/08

1441.5
1479.5
1517.5
1555.5
1593.5
1631.5
2011/04/07

1669.5
1707.5
1745.5
1783.5
1821.5
1859.5
2011/04/06

1897.5
1935.5
1973.5
2011.5
2049.5
2087.5
2011/04/05

2125.5
2163.5
2201.5
2239.5
2277.5
2315.5
2353.5
2391.5
2429.5
2467.5
Rope Position in Shaft [m]

4
 WHY CRMS ?
IMPROVE SAFETY

INCREASE PRODUCTION

INCREASE ROPE LIFESPAN

ENHANCE ROPE INSPECTIONS

ENHANCE MEASUREMENTS

5
 IMPROVED SAFETY

Monitor Condition of Rope Continuously

Continuous Built In Test (CBIT)

All exceedences are logged

Immediate notification of alarm exceedences

•Green/Orange/Red indicator lights to winder operator
•Short message service (sms)

End of wind trip

Acknowledgement and logging of corrective action

6
 Manage Rope Safety Factor

Incorporating Percentage
Currently
CRLM and CRCM Change
Safety Factor 4.5 3.9 -13
Payload (kg) 11000 18677 41

Current Calculation Inputs Formulae

• Rope Breaking Strength (Ø) 2200 kN Minimim Safety Factor = 25 000 m / (4000 m + l)
• Conveyance Mass (m1) 9210 kg Safety Factor = Ø / (g * (ρl + m1 + m2))
• Rope Length (l) 2430 m
• Rope Linear Density (ρ) 12.26 kg/m
• Graviational Acc. (g) 9.81 m/s2
• Payload Mass (m2) 11 000 kg

41 % Increase in Load
7
 INCREASE PRODUCTION
Cycle

Manage safety factor - Increase load – 41 %

Optimize cycle - Monitor loading

Schedule & Optimize maintenance

Planned preventative rope maintenance based on rope usage

and trend analysis – (Rope replacement)

Measure rope condition at operational speed – 20 m/s

? ?

Cycles vs Time
8
 Enhance Rope Inspections

Rigger daily inspections

Shaft Engineer monthly inspections

Mobile Rope Health Inspections

Remote inspection capability – (Internet)

Temporal / Historical data analysis – new dimension

9
 Increase Rope Lifespan

Dynamic Loading – Adapt Operational Procedures
• Acceleration / Deceleration
• Loading / Unloading
• Rope coiling crossovers
• Rope layer crossover

Rope Dressing Optimization

Optimum Back End Cutting - Lenght and Frequency

Sheave groove profiling

Effects of Shaft condition and movement evident

“Light Colors” = Loaded Up Runs

“Dark Colors” = Empty Down Runs

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 CRMS – Trend Analysis

Empty Down Runs

Winder Control

Loaded Up Runs

11
 Enhance Measurements

Effect of rope installation

Comparison to manufacturer rope report

New Rope Discard Criteria

SANS Review

New Rope Safety Factors

Condition algorithms upgrade

Easy, effective real time reporting

Slack Rope – Tight Rope

Monitor loading

12
 Major Components

13
 Built In Test - BIT

14
 Current CRMS Capabilities
Maximum Rope Length: 5000 m
Rope Position Resolution: < 5 mm
Maximum Rope Speed: 30 m/s
Area Resolution: > 1m, < 5m rope length
Local Area Resolution: < 0.33 m rope length
Broken Wire Resolution: < 0.33 m rope length
Raw Data Storage Period: 30 days
Rope Health Data Storage Period: 10 years

15
 Rope Corrosion

Corrosion at
Rope
Crossovers

Winder Drum Circumference

16
 Broken Wire Test

Added Ø 0.8 mm Wire

@ 16 m/s

Ø 3.3 mm
Ø 1.68 mm

17
 Broken Wire - Max Rope Speed Test

Wire Start
Broken Wire Raw Measurement

Wire End

18
 CRMS Real Time Display

19
 SCADA

20
 Winder / Rope Display

21
 Rope Movement

22
 Events History Log

23
 Rope Maintenance History

24
 Future Development

Rope Health Algorithm Improvement

Testing of the dead ends continuously

Expand capability to incorporate the following:
• Chair-lifts
• Elevators
• Walking Draglines
• Aerial Cableways
• etc

25