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In Situ Non-destructive Testing of Man Riding Chair Lift System

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DOI: 10.1007/978-981-15-2647-3_3

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Chapter 3
In Situ Non-destructive Testing of Man
Riding Chair Lift System

Mohd Ahtesham Hussain Siddiqui, Anil Kumar Agrawal

and Somnath Chattopadhyaya

Abstract Man riding chair lift (MRCL) system is a transportation media for the
people working in underground mines. Underground mines are opened in two ways:
shaft sinking vertically from the surface to the coal seam and through an incline
drifted horizontally following some gradient pattern normally 1:4.5 up to the coal
seam. People have to travel a long distance to reach up to the working faces in
underground mines through the incline. This long travelling distance consumes more
time and energy to reach working places. Due to that, the miners get tired. Production
losses are incurred due to less working hours and inefficiency of workers. MRCL is
installed to facilitate the people working in underground mines. It reduces man effort
to reach the face and also saves time. Non-destructive testing of MRCL is mandatory
to ensure the safety of the people. In this paper, ultrasonic flaw detection technique
and liquid dye penetration test were conducted for NDT of MRCL.

Keywords Man riding chair lift · Non-destructive testing · Ultrasonic flaw

detection technique · Liquid dye penetration testing

3.1 Introduction

Coal production from underground mines is a tedious job. In bord-and-pillar method

of mining, we have to go advanced day to day during the development of coal seams.
Miners have to walk long, about 3–4 km, on the uneven, gradient surface, maximum
depth (RL-132) of 200 m from the surface (RL-332) for reaching working places. This
travelling distance enhances with progress in coal faces. The productivity of people
goes down as we move ahead. Their time and energy are wasted in this unproductive
work of walking [1]. Coal Mines Regulations, 2017, Regulation 93(6) stated that “In

M. A. H. Siddiqui (B) · A. K. Agrawal · S. Chattopadhyaya

Indian Institute of Technology (Indian School of Mines), Dhanbad, India
M. A. H. Siddiqui
Coal India Limited, Western Coal Fields Limited, Saoner, Nagpur, India
M. A. H. Siddiqui · A. K. Agrawal · S. Chattopadhyaya
Springer Heidelberg, Tiergartenstr. 17, 69121 Heidelberg, Germany

© Springer Nature Singapore Pte Ltd. 2020 27

S. Yadav et al. (eds.), Proceedings of International Conference in Mechanical and Energy
Technology, Smart Innovation, Systems and Technologies 174,
https://doi.org/10.1007/978-981-15-2647-3_3
28 M. A. H. Siddiqui et al.

case the travelling distance from the incline or adit mouth or pit bottom exceeds one
kilometre or the travelling is arduous, the owner, agent and manager shall provide
suitable man-riding arrangement as approved by the Chief Inspector, within one year
from the date of coming into force of these regulations” [2]. Therefore, a system was
designed which increases the effectiveness of utilisation of workmen with reducing
the drudgery of walking. MRCL is a device utilising for transporting of the workforce
to mines and back. MRCL was manufactured by M/s Indicon Westfalia Limited and
installed in incline No. 6 of Saoner Mine No. 3, Nagpur Area, Western Coalfield
Limited. The total length of man rider is 1003 m from the surface with a vertical lift of
105.04 m. Its drive head is at the surface (RL-332.90) and tail end at 21 Rise/0 Level,
Seam V (RL-227.86). The chair lift system for man riding is an electrohydraulically
operated and an endless haulage-type machine, equipped with all statuary safety
devices. Induction motor (110 KW, 550 V, 1450 rpm) used as a prime mover to
give torque to the axial piston pump with swash plate. A pump delivers 298 L/min
of hydraulic fluids up to maximum 400 bars to the high-torque hydraulic motor,
which transmits torque to the drive sheave. MRCL consists of two main pulleys,
one driving station and one at the return station on which the rope is roaming for
endless operation. These pulleys can bear the maximum loading capacity of the rope.
While testing of hydraulic brakes’ effectiveness, maximum torque is applied by the
hydraulic pump via high-torque hydraulic motor on the driving pulley. It can stand
against that maximum torque and load, without shear or weld failure.
In situ investigation via NDT technique can be done to ensure feasibility, reliability
and integrity of all vital parts of MRCL. A vital component of MRCL can bear and
transmit load, without impairing their originality, structural changes, physical and
chemical properties and usefulness. NDT is the best engineering tool for detecting a
flaw or defect developing and inherently present in the system. It is an economical and
time-saving procedure. On that basis, the testing, safety and reliability of machines
can be ensured [3].
An objective behind this research work of NDT is to ensure the intactness of
MRCL vital component which bears the maximum load [4]. Examine the component
for any discontinuity due to inhomogeneity. The discontinuity can be developed in
any stage, during the life cycle of the component. This may be present inherently
or developed in processing or during providing services. NDT can ensure the actual
condition of the component; it provides information on defects whether present or
developed internally. NDT evaluates the levels of reliability, materials’ behaviour and
internal characteristics of a test piece without impairing their operational condition
and structural dimensions [5]. NDT suggests us to go for further use or needs some
repairing or replacing of the tested components. MRCL is installed to facilitate the
people working in underground mines. It reduces man effort to reach the working
places and also saves time. Non-destructive testing of MRCL is mandatory to ensure
the safety of the people and machines itself. Figure 3.1 indicates the line diagram of
MRCL system used in transportation media for the people working in underground
mines.
3 In Situ Non-destructive Testing of Man Riding Chair Lift System 29

Fig. 3.1 Line diagram of MRCL system

3.2 Literature Review

Wahed and Farhan [6] performed an investigation of non-destructive testing of the

pressure vessel. They utilised ultrasonic flow detection and magnetic particle testing
techniques for checking long seam weld and circumferential seam weld, undercuts,
porosity and hairline cracks. No defect was found in the pressure vessel. Some lim-
itations are there for checking the varying cross-sectional parts and high-current
magnetising effects in magnetic particle testing. Various cross-sectional jobs could
not be tested by ultrasonic flow detection techniques. Pohl et al. [7] investigated NDT
techniques for railroad wheel and gauge corner inspection. They performed in situ
inspection of rail load wheel and gauge corner especially of high-speed trains to
ensure safety norms of wheels with mechanised or non-destructive inspection sys-
tems. Ultrasonic wheel inspection technique and eddy current techniques were used
to inspect the wheel and railway gauge corners, respectively. Gholizadeh [8] reviewed
non-destructive testing methods of composite materials. In this review study, vari-
ous techniques are analysed based on their capabilities and account their advantages
and disadvantages. NDT techniques, such as visual testing, thermography, radio-
graphic testing, ultrasonic testing, acoustic emission, electromagnetic testing and
thermography tests, were engaged for performing these methods. These techniques
are characterised based on their intrinsic characteristics and applications. Singh et al.
30 M. A. H. Siddiqui et al.

[9] did a review of MRCL system effectiveness in underground coal mines with ref-
erence to Ballarpur Colliery 3 and 4 pits using rank–weight method. They suggest
the basic safety features to be included with the system for riskless operation of the
man riders.

3.3 Test Techniques

NDT of MRCL system was done by two methods: (i) ultrasonic flaw detection
technique and (ii) liquid dye penetration technique.

3.3.1 Ultrasonic Flaw Detection Technique (UFDT)

Ultrasonic flaw detection/Ultrasonic testing of a component consists of sending a

beam of energy into the component. High-frequency sound energy (between 0.5 and
10 MHz) is propagating from the transducer into the testing specimen. The speed
of propagation is proportional to the density and elastic behaviour of the medium.
Ultrasonic waves are reflected from a dissimilar surface or interface. This is the
working principle of ultrasonic waves used in UFDT. The amount of reflection of
ultrasonic waves from interfaces depends on the acoustic properties of the material.
Laws of light are followed by the ultrasonic waves. These waves are generated from
the transducer, which transforms electrical signals to mechanical vibration and vice
versa. These waves collect information and displayed on a cathode ray tube. The
cathode ray tube is calibrated to enable accurate thickness measurement of locating
the defect. Height, amplitude and percentage of the reflected waves are given the
exact orientation and size of the defects. Figure 3.2 shows the line diagram of UFDT
set-up. The drive sheave pin and return pulley shafts were tested by UFDT.

Fig. 3.2 Line diagram of UFDT set-up

3 In Situ Non-destructive Testing of Man Riding Chair Lift System 31

3.3.2 Liquid Dye Penetration Testing Technique (LDPTT)

It is the most widely used non-destructive testing technique for the detection of
surface flaws by a capillary phenomenon. In this NDT technique, the liquid form of
penetrant is spread over the cleaned surface of the test specimen which was cleaned
by cleaner or remover and waits for the next ten minutes. This liquid can be penetrated
effectively in the surface discontinuities vicinity. The capillary phenomenon helps
in finding the surface discontinuities, cracks and blowholes or pinhole.
After ten minutes, clean the surface with cleaner and then spray the contrast colour
developer on the surface. If any discontinuity is there, penetrant comes out from the
vicinity of defects. Shape and size of contrast colour penetrant show the intensity of
defects or cracks.

3.4 Testing

3.4.1 Ultrasonic Testing Process of NDT

Ultrasonic testing process of NDT follows the reference standard ASME Sec. V, Arti-
cle 4, ASTM A609 for test procedure and ASME Sec. VIII, Div.1 Apx-12 (welding
checking with angle probe) for acceptance standard. Equipment used was Digiscan
DS-322 with the pulse-echo method with a light intensity of 1080 lx. The differ-
ent probe is shown in Fig. 3.3. Table 3.1 presents a different parameter of UFDT.
Figure 3.4 shows the different test of UFDT, and Fig. 3.5 presents the procedure of
testing.

Fig. 3.3 Image of types of probes

Table 3.1 Specification of MRCL

Range Speed Capacity Vertical gradient Horizontal curve
2000 m 0–2 m/s 200 person/h 1:4.5 maximum 15–120°
32 M. A. H. Siddiqui et al.

Fig. 3.4 Photographs of conducting ultrasonic flaw detection of MRCL

Fig. 3.5 Flowchart of UFDT testing procedure

3 In Situ Non-destructive Testing of Man Riding Chair Lift System 33

Fig. 3.6 Images of sprays used in dye penetration test

3.4.2 Liquid Dye Penetrant Test Process of NDT

Liquid dye penetrant test process of NDT follows the reference standard ASME Sec.
V, Article-24, SE-165 (IS3658-1999) for test procedure and ASME Sec. VIII, Div.1
Apx.8 for acceptance standard. The light intensity is of 1080 lx. Cleaner/Remover
used was SKC-1, Batch No. 19A02, Brand Name: Spotcheck (Magnaflux), Manufac-
turing Date: January 2019, Due Date: December 2021, Cleaning Time: 05 min, done
with lint-free cloth and cleaner. Penetrant used was Solvent Removable-type SKL-
SP1, Batch No. 18F15, Brand Name: Spotcheck (Magnaflux), Manufacturing Date:
June 2018, Due Date: May 2020, Dwell time: 10 min. The Developer used was
SKD-S2, Batch No. 18J03, Brand Name: Spotcheck (Magnaflux), Manufacturing
Date: September 2018, Due Date: July 2020, Developing Time: 1–2 min. Figure 3.6
shows liquid dye penetrant bottles.
Figures 3.7 and 3.8 show the use of liquid dye penetration on MRCL. Figure 3.9
shows the flowchart of liquid penetration test procedure. Different parts of MRCL
were tested by NDT. Figures 3.10, 3.11 and 3.12 show the different components
of MRCL. Table 3.2 presents the different components of MRCL on which NDT
performed.

3.5 Result

All the above components (Table 3.3) of MRCL gone under NDT with UFDT and
LDPTT, whichever applicable mentioned in front of those components. The NDT
was conducted as per ASME and ASTM references, as mentioned in Tables 3.4 and
3.5. The ultrasonic test reported that no recordable indication was observed. Hence,
the result was satisfactory as per the above-mentioned acceptance standards. Liquid
penetrant test report stated that no surface discontinuities were observed. Hence,
the results are satisfactory as per the above-mentioned standards. Except for Chair
No. 66 Bracket with handle—Identification No. WCL/SAON-143 and Chair No. 77
34 M. A. H. Siddiqui et al.

Fig. 3.7 Spraying penetrant on drive sheave

Fig. 3.8 Spraying developer on drive sheave

3 In Situ Non-destructive Testing of Man Riding Chair Lift System 35

Fig. 3.9 Flowchart of liquid penetration test procedure

Bracket with handle—Identification No. WCL/SAON-16 were faulted. A 50- and

70-mm welding surface cracks were found (Fig. 3.13), respectively. These cracks
were welded with suitable welding electrodes, and the Chair Nos. 66 and 77 can be
utilised for further use.
36 M. A. H. Siddiqui et al.

Fig. 3.10 Drive unit of MRCL. 1. Frame, 2. disc brake, 3. drive sheave, 4. drive sheave lining,
5. hydraulic motor connection set, 6. high-pressure line connection, 7. leakage line connection, 8.
hydraulic motor

Fig. 3.11 Brake assembly of MRCL 1. Mounting, 2. hydraulic cylinder, 3. intermediate lever, 4.
upper brake lever, 5. lower brake lever, 6. brake shoe, 7. brake pad, 8. adjusting screw, 9. lock nut

Fig. 3.12 Return station of MRCL 1. Beam, 2. return pulley, 3. lining, 4. trolley, 5. wing, 6.
tensioning pulley, 7. adjusting bolt, 8. counter nut, 9. pin, split pin, washer, 10. pin, split pin,
washer, 11. pin, split pin, washer, 12. pin, split pin, washer, 13. fastening bolts, 14. cover, 15. split
pin, 16. adjustable nut, 17. bearing

3.6 Conclusion

Underground coal mines are governed by Coal Mines Regulation 2017. Director-
General of Mines Safety (DGMS), Directorate General of Mines Safety, Dhanbad,
India, is the inspecting and permitting authority for installation and use of MRCL.
3 In Situ Non-destructive Testing of Man Riding Chair Lift System 37

Table 3.2 UFDT testing specification

Probe Frequency Input pulse Couplant Pulse Calibration Sensitivity
and waves energy block
(dB)
Normal 4 MHz Ø10 mm Oil 42 dB IIW V1 and 100% FSH
probe Longitudinal (36 + V2 block +06 dB
6)
Normal 2 MHz Ø24 mm Oil 40 dB IIW V1 and 100% FSH
probe Longitudinal (34 + V2 block +06 dB
6)

Table 3.3 Components of MRCL on which NDT performed

S. No. Component description Qty in nos. UFDT LDPTT Identification number
1 Drive sheave casting 01 Done Done WCL/SAON-01
2 Return wheel casting 01 Done Done WCL/SAON-13
3 Bottom pin of drive 01 Done – WCL/SAON-02
sheave
4 Brake assembly pins 05 Done – WCL/SAON-03 to 07
5 Turn buckle assembly 02 Done – WCL/SAON-08 to 09
6 Pin of brake shoe 02 Done – WCL/SAON- 10 to 11
7 Eye bolt 01 Done – WCL/SAON- 12
8 Return wheel shaft 01 Done WCL/SAON-14
9 Man rider chair with 150 Done Done WCL/SAON-15 to 311
bracket pin
10 Carrying pulley shaft 90 Done – WCL/SAON-T01 to
T90

Table 3.4 UFDT test report

Surface Material Procedure Acceptance Equipment Method Light
condition description ref standard used used intensity
of the part standard
Smooth Steel ASME ASME Sec DS-322 Pulse-echo 1080 lx
Sec. V VIII Div. 1 contact
Article-4 Apx-12 type
ASTM
A609

DGMS permitted for the use of MRCL in underground mines under Regulation
208(4) of CMR 17 after conducting NDT on its vital parts. Non-destructive testing
conducted on MRCL to ensure whether load bearing components are in intact con-
dition and safe for the operation of transportation of people in the underground, both
level and gradient of mines. UFDT and LDPT are conducted as an NDT of MRCL.
38 M. A. H. Siddiqui et al.

Table 3.5 Liquid penetrant test report

Surface Procedure ref Acceptance Cleaning Penetrant Developer
condition standard standard application application application
of the part
Smooth ASME Sec. V ASME Sec. Lint-free Removable SKD-S2,
Article-24 VIII Div. 1 cloth and solvent Batch No.
SE-165 Apx-08 cleaner (SKL-SP1, 18j03, Brand
(IS3658-1999) (SKC-1, Batch No. Name
Batch No. 18F15, Brand Spotcheck,
19A02, Name Magnaflux
Brand Name Spotcheck,
Spotcheck, Magnaflux)
Magnaflux)

Fig. 3.13 70- and 50-mm welding surface cracks on chairs

Result of these tests ensures for continuing the use of MRCL for transporting miners
in underground mines for the further next six months.
Few limitations are there in ultrasonic testing procedure of NDT. We cannot test
the material which unable to transmit ultrasound waves. The velocity of sound waves
propagation is fixed for every material and depends upon the elastic properties and
density of parent material. Thickness, permeability, grained structure and shape of
the material to be tested can create difficulty in ultrasonic testing. Thin size, course-
grained structure and irregular shapes’ components are difficult to check by ultrasonic
method of NDT testing. The orientation of the defects concerning the sound beam,
size, nature and distribution of the defects within the test material can affect the
ability to detect the flaws. Large surface area test piece can consume more time for
testing, and therefore, this technique is expensive. Highly skilled and experienced
manpower is required to conduct the UFDT as compared with other methods of NDT.

Acknowledgements Authors are thankful to Shubham Enterprises, Nagpur, for helping in

conducting NDT on MRCL.
 3 In Situ Non-destructive Testing of Man Riding Chair Lift System 39

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