Significantly improve the online real-time automatic monitoring of steel wire rope for transportation equipment

　　Report on Economic Benefit Analysis of the Steel Wire Rope Safety Management System

Jizhong Energy Fengfeng Group, in order to solve the safety bottleneck of steel wire rope lifting in coal mining enterprises, adopted the "TCK.W Steel Wire Rope Online Real-time Automatic Detection System" created in China, which effectively solved the technical difficulties of steel wire rope detection, eliminated a major safety hazard, and demonstrated an outstanding demonstration effect. This transformation of scientific and technological achievements of Fengfeng Group only directly invested more than one million yuan, increased annual benefits by nearly 300 million yuan, achieved a high return of 1:300, created a successful case of using science and technology to promote enterprises, and provided us with valuable innovative experience.

　　According to the comprehensive analysis data on the national coal production safety situation released by the State Administration of Work Safety, there         were 509 coal transportation and lifting accidents in coal mines nationwide in 2010, resulting in 559 deaths. In 2009, there were 556 coal transportation and lifting accidents in coal mines nationwide, resulting in 583 deaths. From January to May, there were more than 215 serious and extra serious accidents caused by steel wire rope problems in the national coal system, resulting in 223 deaths, of which the most serious was a steel wire rope failure accident in Shanxi Luliang with 14 deaths and 5 seriously injured people.

　　In addition, according to the statistics from "China Coal Mine Accidents and Expert Reviews Collection", by the end of the last century, transportation and lifting accidents in coal mines across the country had resulted in 19,871 deaths, accounting for 15.06% of the total death toll. It was only second to roof and gas accidents and was the third major disaster accident in the coal system. During this period, state-owned key coal mines had a total of 91 transportation and lifting accidents with more than 3 deaths each, resulting in 421 deaths. Among them, 34 were steel wire rope failure accidents, accounting for 37.36%, resulting in 193 deaths, accounting for 45.84%.

　　As a major type of metal component with specific uses, the use of steel wire rope often involves significant property and personal safety for businesses or individuals. However, in the current situation of lack of rigorous testing and management conditions, a large number of steel wire ropes in use are still in an uncontrolled state. The unsafe, uneconomical, and inefficient use of steel wire rope is a serious issue commonly reported by enterprise and equipment management departments in various industrial fields.

　　At present, the detection of steel wire ropes relies on visual inspection, hand feel, and caliper measurement. Visible damage requires good experience and judgment from detection technicians to detect, while latent damage is almost impossible to capture and reveal. Due to the inability of traditional detection methods to quantitatively describe the damage of in-service steel wire ropes, a more serious situation is that although the performance of in-service steel wire ropes is constantly in a state of irreversible deterioration, it is still impossible to accurately measure the severity of this deterioration. Therefore, there are hidden safety hazards caused by the residual load capacity approaching the limit, as well as unnecessary economic losses caused by the lack of scientific basis for premature scrapping. Blind spots and difficulties also exist in the management of in-service steel wire ropes. From design, selection, manufacturing, factory departure, installation, operation, maintenance, transportation, storage, to scrapping and replacement, there are conceptual deviations, short-term behavior, monitoring blind spots, and inappropriate management habits related to steel wire ropes and related equipment and facilities. Although detection methods are one reason, how to "treat the symptoms" and "cure the disease" is also a concern and obstacle for equipment management departments.

　　At the same time, there are other blind spots and difficulties in the management of in-service steel wire ropes. From the design, selection, manufacturing, factory departure, installation, operation, maintenance, transportation, storage, scrapping, and replacement of steel wire ropes and related equipment and facilities, there are conceptual deviations, short-term behavior, monitoring blind spots, and inappropriate management habits. Detection methods are only one reason. How to "treat the symptoms" and "cure the disease" is also a concern and obstacle for equipment management departments.

　　For equipment users, the management of steel wire ropes faces many bottlenecks: first, the operating environment is often relatively adverse, which increases the uncontrolled factors in equipment management and makes the management more difficult; second, enterprises continue to pursue high efficiency and high benefits in production, which further increases the equipment load; third, the commonly used detection methods still cannot allow managers to accurately grasp the technical status of steel wire ropes and related equipment and facilities; fourth, the maintenance and overhaul of steel wire ropes and related equipment are time-consuming and labor-intensive, which greatly squeezes production operation time and requires high costs; fifth, safety responsibility is extremely important, but steel wire rope breaking accidents still repeatedly occur, causing significant harm and impact and losses that cannot be ignored.

　　Since the beginning of last year, we have conducted research and development work on the "Real-time Online Monitoring and Safety Management System for Major Elevating Transportation Equipment Steel Wire Ropes" in collaboration with Luo Yang Wire Rope Inspection Technology Co.,Ltd. The total investment in research and development is 1.28 million yuan. The system adopts China's independently innovative and internationally leading weak magnetic detection technology, and is customized based on the actual work environment and safety operation needs of major lifting transportation equipment. It is equipped with technical functional units such as pattern combination detection unit, multi-function data acquisition and conversion unit, acoustic-visual warning unit, and terminal program main command control unit. The indoor terminal intelligent control type can monitor steel wire ropes in real-time. The system's online monitoring of steel wire ropes is based on command-controlled weak magnetic quantitative non-destructive testing, which has high-resolution capabilities for internal and external fatigue, broken wires, wear, corrosion and other damage of in-service steel wire ropes. This effectively solves the various drawbacks of manual inspection methods for steel wire ropes and provides new technical support for achieving "safe, efficient, and cost-effective" operation of important facilities and major equipment.

　　Through the joint efforts of both parties in the past two years, the project has made significant progress. The technical achievements have been successfully applied to the production site of Fengfeng Group, providing strong safety guarantees for production units and equipment management departments. It has also demonstrated prominent social and economic benefits.

　　一、social benefit

　　Compared with traditional steel wire rope detection and management methods, the "Real-time Online Monitoring and Safety Management System for Major Elevating Transportation Equipment Steel Wire Ropes" effectively strengthens the safety protection effect of steel wire ropes in eight major aspects:

　　The establishment and operation of the steel wire rope database and management system will completely change the outdated steel wire rope management theory and methods of the past, which is of great significance to safe production. By implementing the full-process detection, monitoring, maintenance and other management systems, the essential safety level of major lifting transportation equipment in mines will be greatly improved, and effective prevention of lifting safety accidents will be achieved. Its safety and social benefits are significant.

　　二、economic benefits

　　After implementing the "Real-time Online Monitoring and Safety Management System for Major Elevating Transportation Equipment Steel Wire Ropes" for major lifting transportation equipment, in addition to the safety avoidance benefits, the economic benefits of enterprises are also highlighted in three main aspects: improving the efficiency of equipment production and operation, eliminating manual detection energy consumption, and saving steel wire rope usage.

　　1、Improve equipment production and operation efficiency

　　According to regulations stipulated in Article 391 of the "Coal Mine Safety Regulations", "the lifting steel rope and guide rope must be inspected once a day", and manual inspection shall be carried out with a rope speed not exceeding 0.5m/s. In the past, it took one hour to inspect the steel rope in Dushucun Mine and Jiulong Mine of Fengfeng Group, and one hour for Xuecun Mine. If there were any abnormalities in the steel rope, the inspection time would be even longer. After adopting the online real-time safety monitoring and management system for steel wire ropes, each mine can increase production capacity by at least 6.3% per year, with an additional output of at least 9.4, 13.1 and 6.3 tons per year for the three mines respectively, amounting to a total of 28.8 tons.

　　According to the comprehensive price of coal in October 2011 of 1000 yuan/ton, adopting this system will increase output value by 288 million yuan under the same work schedule system.

　　2、Eliminate manual inspection energy consumption

　　Through on-site measurement, it is found that Fengfeng Group's Dushucun Mine has a lifting height of 780m and uses a four-rope friction winder with an electric motor of 800kw × 2. When manually inspecting the rope, the rope speed is 0.3 to 0.5m/s, the actual power consumption is 386kw, and it takes 579kwh to complete a manual inspection. Two inspectors synchronously test, and it takes 1040kwh of electricity per day to complete one round of testing. Jiulong Mine has the same situation as Dushucun Mine, and Xuecun Mine has a lifting height of 220m and uses a single-rope winding winder with an electric motor of 630kw × 1. When manually inspecting the rope, the rope speed is 0.3 to 0.5m/s, the actual power consumption is 152kw, and it takes 152kwh of electricity per day to complete a manual inspection.

　　Therefore, the total daily energy consumption for the three mines during rope inspection reaches 2200kwh. Based on the approved working hours of 330 days per year, the annual idle energy consumption for steel wire rope inspection alone reaches at least 726,000kwh, which does not include the energy consumption during maintenance shutdown.

　　After adopting the "Real-time Online Monitoring and Safety Management System for Major Elevating Transportation Equipment Steel Wire Ropes", there is no need to start the machine daily for inspection. Based on the local industrial electricity price of 2.7 yuan/kwh, this alone can save an annual energy cost of 1.96 million yuan.

　　3、Saving steel wire rope usage

　　Take Dushucun Mine as an example, the cost of replacing the main shaft lifting rope once is 400,000 yuan, with a labor cost of 250,000 yuan, and the shutdown and adjustment time for the net shortening of the operation reaches 5 days. After adopting the "Real-time Online Monitoring and Safety Management System for Major Elevating Transportation Equipment Steel Wire Ropes", it provides a new technical verification possibility for extending the actual service life of steel wire ropes (currently, according to the "Coal Mine Safety Regulations", the actual replacement cycle of steel wire ropes remains unchanged at 2 years).

        Coal mine safety

　　If we consider the overall level of Jizhong Energy Fengfeng Group, in previous years, the steel wire rope usage was about 1,240 tons, with a cost of approximately 10.5 million yuan. Actually, annual unexpected accidents caused by steel wire rope account for a considerable proportion, and it is initially estimated to be about one-third. After adopting the "Real-time Online Monitoring and Safety Management System for Major Elevating Transportation Equipment Steel Wire Ropes", it has been a reality to save on the cost of steel wire rope usage, about 2 million yuan per year.

　　In summary, the adoption of the steel wire rope online real-time safety monitoring and management system has improved the inherent safety level of equipment, reduced maintenance time, increased production, saved energy and material costs for inspection and rope replacement, and directly achieved economic benefits of nearly 300 million yuan. Its safety benefits are even more considerable. This is a major application and promotion of advanced technology in the safety of lifting transportation equipment, and it is an excellent technical solution for improving transportation equipment safety.