Machine Health Monitoring
Machine Health Monitoring

HORG : RUDRA PRATAP SINGH

This is a group of scientists and technical staff working for development of mine machinery used in coal and non-coal mines. The performance evaluation of mine machinery to ensure safety in mines has been undertaken on large scale. Apart from mining industries other industries like oil, gas, wire rope & electric cables etc. has also been associated for the quality assessment of their products. The group comprises of:

1. Metallurgy

2. Material Testing Laboratory & Workshop

3. Roof Support Testing Laboratory

There are total four numbers of Gr (IV) scientists, three numbers of Gr (III) technical staffs, and two numbers of Gr (II) staffs and senior technician person belongs to the group other that project fellow and temporary staff. The group have multidisciplinary manpower subject wise comprises of Chemistry, Mechanical engineers and Metallurgical engineers. The group has developed excellent knowledge and experience on R & D for development of mining engineering appliances and its safety monitoring


Section 1: Metallurgy

The Metallurgical Laboratory of CIMFR (HQ) is well known for its testing of various equipment/appliances used in Mining and Allied Industries. Apart from testing, various R & D activity particularly failure analysis of mining engineering equipments or components are being carried out in the Department. The focus area of the laboratory is:
Performance evaluation of metallurgical properties of mining engineering appliances like cage suspension gear, winding rope, electrical cables, rope cappel, tub, bridle chain etc. with regards to its metallurgical properties for safe operation of mines. Further, failure analysis of mining engineering appliances particularly wire rope and cage suspension gear and its components are being carried out as per different BIS/IS code and DGMS guidelines. A large scale mine fire model gallery has been designed and developed under S& T project “Studies on simulation of open fire in Mine Fire Model Gallery under varied airflow for suppression of fire and explosions in underground coalmines” .The coal fire studies, diesel fire studies have been carried out in the gallery and developed HPHS fire suppression technology to control coal mine fire. Further a suitable heating device have been developed for 1.5 m long pressure tube -calendria tube (PT-CT) deformation study under simulated heating condition. The experiments were carried out to enhance the safety of nuclear power plants.

MANDATE OF THE SECTION:

  1. Performance evaluation of metallurgical properties of mining appliances like cage suspension gear, winding rope, electrical cables, rope cappel, tub, bridle chain etc. with regards to its metallurgical properties for safe operation of mines.
  2. Failure analyses of mining engineering appliances particularly wire ropes and cage suspension gear and its components are being carried out as per different BIS/IS code and DGMS guidelines.

IMPORTANT ACHIEVEMENTS OF THE SECTION (around 200 words):

  1. Study and advice on life- expediency of steel wire ropes for safe use in mines
  2. Test and certification of mining & allied engineering equipments
  3. Studies on simulation of open fire in mine gallery under varied air flow for suppression of fire and explosions in underground coal mines.
  4. Development of HPHS nitrogen foam technique to control coal mine fires.
  5. Designing of a suitable heating device for pressure tube-calandria tube (PT-CT) and its deformation study under simulated heating condition.
  6. Diesel fire study at CIMFR Mine Fire Model Gallery.
  7. Failure analysis of mine engineering components specially wires rope.
  8. Created state-of-the art facilities like optical emission spectrophotometer, Image analyzer, automatic grinding & polishing machine etc. to assess the condition of mine engineering appliances in more precise way.

Section 2: Materia Testing Laboratory & Workshop

DEPARTMENTAL ACTIVITIES:

  1. R&D of mining and allied engineering equipment;
  2. Study and advice on soundness of mechanical integrity of mine hoisting systems / man riding systems;
  3. Failure analysis of mining & allied engineering equipment in general but wire rope in particular;
  4. Evaluation of physico-mechanical properties for performance behaviour of roof bolt, W-strap, hydra-bolt, safety belt, wire ropes etc. including BIS samples;.
  5. Study and advice on life-expediency of steel wire ropes for safe use in mines;
  6. Testing & certification of mining & allied engineering equipment.

ENGINEERING WORKSHOP:

Objectives of this department are as follows:

1) To maintain the quality of the maintenance job and complete the job within 10 days

2) To maintain the quality of the fabrication work, complete the job within the time period given by the indentor for the different job.

Major Achievement :- Two Patents already filed from Workshop, two patents are in process to file. Technology of one patent “ Coal Dust Collection and Brequetting System” has been commercialized.

  1. HMT Lathe machine 16” swing, 6’ bed
  2. TLV Lathe Machine 22” swing, 6½’ bed
  3. Box Ford Lathe Machine 8” swing, 4’ bed
  4. COLCHESTER Lathe Machine 10” swing, 4’ bed
  5. Milling machine
  6. Grinding machine wheel dia 12”
  7. Power hack Saw 5”
  8. Power Hack Saw 8”
  9. Bench Drill machine ¾”
  10. Surface Grinding Machine, wheel dia 10”, Bed stroke 4”

 

  1. Radial Drill Machine 1½”
  2. Bench Drill Machine ½”
  3. Welding Transformer 19 amps
  4. Welding Generator Set 300 amps.
  5. Three Roller Bending machine  ½” thick
  6. Nibbling machine 12 gauge
  7. Air Compressor 4kg / cm2
  8. SAGAR Shaping Machine 24”
  9. ELLOT Shaping Machine 18”
  10. Hydraulic Press Machine  6 T

Section 3: Roof Support Testing Laboratory

This section is working in design & development of mining and allied engineering components. Additionally, this section has having expertise of manufacturing engineering as well as assessment of mechanical properties of materials. Quality evaluation of roof support equipments e.g steel prop ( Rigid & Yielding) steel cogs, concrete sleepers, pit bottom buffer etc. and assessment of mechanical integrity of components are also assessed in this section. Apart from these this section has sufficient expertise for IPR generation and Quality Management System including internal auditing as per NABL & ISO9000. This section has made significant R&D contributions in the thrust area (underground coal mining) of CSIR-CIMFR on the basis of following available skill and expertise:

1. Knowledge and understanding of Artificial Intelligent Techniques for optimization of design parameters.

2. Investigational studies for failure of the components in industries by stress analysis.

3. Skill and expertise for design & development of underground mining components and quality analysis by destructive & non-destructive techniques thereof.

4. Assessment of physic-mechanical properties of all roof support equipments, concrete sleepers, pit bottom buffer etc.

5. Knowledge and experience for innovations, invention of new mining machinery items, novel idea to design & development and their fabrication techniques with IPR generations.

6. Knowledge of commercialization of developed new technologies.

7. Experience & expertise for NABL and ISO9000 QMS & internal quality auditing.

MANDATE OF THE SECTION:

R&D for safe and efficient underground coal mining by installing qualitatively proven roof support and other allied engineering equipments including design, development & fabrication of new innovative mining machinery components

IMPORTANT ACHIEVEMENTS OF THE SECTION (around 200 words):

This section has expertise for evaluation and investigation of the quality of roof support equipments and other allied engineering components. In addition to that this section has produced about 20 patents ( National & International) and some of them commercialized. This section has also produced one M.Tech and three are pursuing.
It has to his credit more than 70 research publications in various International & National journals/conferences, about 20 International & National Patents filed in 42 countries, 8 Nos. of Technology Transfer.
This section has been associated in more than 40 nos. of government & industry sponsored research project as principal investigators including one Grant-in Aid project of Rs. 1.67 crores approved by
This section has delivered Invited Lectures organized by IIM Ahmedabad , BCCL Dhanbad and IMME Dhanbad. Additionally, He has guided several B.Tech. & M.Tech. students for their projects and acted as external examiner of PhD, M.Tech. students in Utkal University and in the Department of Mining Machinery engineering of ISM Dhanbad respectively.
He has visited Australia, Thailand & Japan in connection with presentation of technical paper at 13th IACMAG , World Tunnel Congress & 14th IACMAG respectively. He has been awarded visiting fellowship by Science & Engineering Research Board (SERB), Department of Science & Technology, Govt. of India & Indian National Science Academy (INSA).


NameDesignationEmail & phonePhoto
Head of the Research Group
Dr. Rudra Pratap Singh

Briefbiodata
Sr. Principal Scientist & Head of the Metallurgy E-mail : rpsingh_cmri@yahoo.co.in
Phone : +91-9471191486 (M)
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Section 1: Metallurgy
Mrs. Mousumi Mallick

Briefbiodata
Scientist E-mail : mousumi.mallick_cimfr@yahoo.co.in / mousumi@cimfr.res.in.
Phone : +91-9204551490 (M)
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Mr. Manoranjan Kumar Verma

Briefbiodata
Technical Officer E-mail : vmanoranjan51@yahoo.com
Phone : +91-9835134282 (M)
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Section 2: Materia Testing Laboratory & Workshop
Dr. Manoj Kumar Singh

Briefbiodata
Sr. Principal Scientist & Head of the Material Testing Laboratory & Workshop E-mail : mkscimfr@gmail.com
Phone : +91-326-2296003/13/27 / Extn. 4276 (O), 09431168908 (M)
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Surajit Dey

Briefbiodata
Sr. Technical Officer (1) E-mail : surajitcmri@gmail.com, surajitcmri@yahoo.co.in
Phone : +91-9431160729 (M)
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Sapan Kumar Mondal

Briefbiodata
Sr. Technician II Phone : +91-9334087969 (M) Service image
B. Ravi Kumar

Briefbiodata
Technical Assistant E-mail : ravicmri_25@rediffmail.com
Phone : +91-8987414895 (M)
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Md. Saleem

Briefbiodata
Sr.Technician (1) Phone : +91-9905735018 (M) Service image
Madan Mondal

Briefbiodata
Gr I (4) Service image
Pawan Hari

Briefbiodata
Gr I (4) Service image
Subhash Kushwaha

Briefbiodata
Temporary Staff Service image
Govind Mahato

Briefbiodata
Lab attendant Service image
Latlu Mahato

Briefbiodata
Lab attendant Service image
Bisheswar Soren

Briefbiodata
T.S Service image
Section 3: Roof Support Testing Laboratory
Prof. (Dr.) Sudhir Kumar Kashyap

Briefbiodata
Senior Principal Scientist E-mail : sudhirnutan@yahoo.com
Phone : +91-326-2296003/10/13/27/28/29 / Extn. 4351 (O) 2296074 (R), 09431120003 (M)
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15 Results
Sl. No.A brief description of Facilities/ Equipment/Tools/software with photos
Section 1: Metallurgy
1

Test facilities 

1.  Wear and corrosion test

2.  Lubrication of wire ropes (Lubricant content)

3.  Macro and micro examination

4.  Chemical analysis

5.  Hardness

6.  Mass and uniformity of zinc coating test

7.  Izod impact test

1.   Wear and corrosion test:

Quantify the wear and corrosion in terms of percentage reduction in diameter of the wire rope and other appliances used in mines.

BIS code used for the above test: 

Round wire IS: 5230-1969 Reaff. 1993 

Shaped wire IS: 3626-1978 

2.   Lubrication of wire ropes (Lubricant content)

Wire ropes used in different mining operation requires lubrication.  Lubrication reduces friction between inpidual wires, between strands, between coils of rope, and between the rope and other surfaces, such as sheaves and drums.

The percentage retention of lubricant (both bituminous and non-bituminous lubricants) on different fibre core is found out.

BIS code used for the above test: 

Fibre main core IS: 6594-2001 

Steel core IS: 3626-2001

3.   Macro and micro examination:

In micro-examination we study:

Inborn manufacturing defects (micro pipe, inclusions, improper microstructure etc.) 

Service degradation (abrasive/plastic wear, pitting corrosion, stress corrosion, martensitic transformation etc.)

Further we critically examine the following parameters to quantify the above:

Phase analysis (area fraction) of various phases present in microstructures. 

Grain size measurements as per ASTM/DIN/JIS specifications automatically in a fraction of second

Non-metallic inclusions as per ASTM standards and also identify the inclusion types like A, B, C, D and inclusion ratings as per DIN, JIS & IS specifications

Total & partial decarburization, crack depth, defect size, banding width, plating/ coating thickness measurements etc.

Nodularity percentage, nodule count, size & distribution

Graphite flake size classification & graphite type percentage as per ASTM

size analysis – area wise and length wise

 

Metallurgical Microscope

4.   Chemical analysis by Optical emission spectrometer (OES)

The State - of - the - art facility has been created recently which can analyzed ferrous, aluminium and copper base alloy up to ppm level within short span of time. The details of the analytical composition of different alloy are as under:

Ferrous base -

The optical emission spectrometer can analyze any composition of ferrous alloy like carbon steel, low alloy steel, Manganese steel, chromium nickel steel or any composition of ferrous based material or alloy. The following elements can be measured up to PPB range:

C, Si, Mn, P, S, Cr, Mo, Ni, Al, Co, Cu, Nb, Ti, V, W, Pb, Sn, Mg, As, B, Zn, N

Aluminium base -

The following elements can be analyzed up to PPB range:

Si, Fe, Cu, Mn, Mg, Cr, Ni, Zn, Ti, B, Be, Bi, Ca, P, Pb, Sn, Sr, V, Zr

Copper base -

The following elements can be analyzed up to PPB range:

Zn, Pb, Sn, P, Mn, Fe, Ni, Si, Mg, Cr, As, Sb, Bi, Al, S, Be

Optical Emission Spectrometer

5.   Hardness

We have Vickers Hardness Testing, Brinell Hardness Testing and Rockwell Hardness Testing machine to determine hardness of ferro alloys as per DGMS guidelines.

BIS code used for the above test:

Vickers Hardness Testing : IS: 1501(pt 1) -1984 2nd rev. Reaff. 1999, IS: 1501 (Part II) 84  reaff. 1989, IS: 1501 (pt III) 87 reaff. 1999

Brinell Hardness Testing:

1500-1983 2nd  Rev. Reaff. 1989

Rockwell  Hardness Testing:

1586-1988 (B+C scale)

 

6.   Mass and uniformity of zinc coating 

Galvanized wire rope has a wide variety of uses. In this type of rope, all of the wires are coated with pure zinc, which forms a protection against corrosion. Here we determined the mass and uniformity of zinc coating of winding rope as well as electrical cables as per DGMS guidelines.

BIS code used for the above test:

IS: 3975-1988 Reaff. 1992, IS: 4826-1979 Reaff. 1998,  IS: 10810(pt. 41) -84Reaff.1996,  IS:    4905-1968 Reaff.1996, IS: 10810 Part 40-84 Reaff. 1992 .

7.   Izod impact test

We have izod impact testing machine to determine the energy absorbed by the material for fracture as per DGMS guidelines.

BIS code used for the above test:

IS: 1598:1977 1st rev.  reaff. 1999

 

TESTING FACILITY AVAILABLE:

A. Physico-mechanical Testing Machines:

  1. 500 T Horizontal Tensile Testing Machine;
  2. 60 T Horizontal Tensile Testing Machine;
  3. 50 T Universal Testing Machine (UTM);
  4. 10 T Universal Testing Machine (UTM);
  5. 10 T Computerized UTM;
  6. 5 T Universal Testing Machine;
  7. 750 kgf Tensile Testing Machine;
  8. Torsion Testing Machine;
  9. Reverse Bend Testing Machine;
  10. Wrap Testing Machine.

B. Non-Destructive Testing Machines:

  1. Universal magnetic crack detector;
  2. Portable magnetic crack detector;
  3. Digital Ultrasonic flaw detector (Testing range up-to 10 m);
  4. Dye penetration testing.

 

Section 2: Materia Testing Laboratory & Workshop
1
Section 3: Roof Support Testing Laboratory
1
 
Sl. No.NameSponsorDurationObjectiveMajor output(if any)
Section 1: Metallurgy
1Study and advice on suitability of wire ropes of mine hoisting system of Khetri Mine & Kolihan Mine of HCL for safe use in future by Metallurgical evaluationKolihan Copper Mines, HCL, Rajasthan (India)06-07-2015 to 04-07-2018

Metallurgical study of wire ropes on suitability in mine hoisting

2Study & failure analysis of ropes used for man riding system in Baherabandh sub Area, Hasdeo Area, SECL (MP).SECL21-03-2012 to 20-03-2014

To investigate the reason/s for failure of the rope.

3Routine testing of mine appliances (Condition Monitorng) for different metallurgical propertiesSamples are coming all parts of IndiaContinued

To ensure the  safety of mine appliance for safe operation of mines

4Development of corrosion protective chemical/technique to prevent ferro-alloy specially mining equipment from corrosionR&D In-house2015-2018

Laboratory study is in progress  on existing (two or three) corrosion protective green inhibitor /technique on ferro-alloy under different mine environment 

4 Results