Professional Documents
Culture Documents
ItandHns
Volume 16
Number 1
January/March 1996
Nondestructive Evaluation
Alex Harrison, USA
Summary
The year 1979 marked the beginning of
a new
cern.
a
as
technology
that
permitted
this
the
composite material Finally, any analysis that does not consider the starting or stopping forces is lacking in terms of complete evaluation of belting condition
are considered to be the optimally correct approach to evaluating belting condition Belt nondestructive testing applies to both steel cord [5] and fabric belting [6] Testing is designed to maximize information about the belting
For the first time, steel cord belts were tested for corrosion and technology has now been in constant commercial use since 1981
-
These directions
belts for
fifteen years The invention of a method to test moving damage and loss of strength led to more complex ap-
plications including broken cable detection and splice signature analysis Fabric belt testing was developed next, followed by cable belt and pipe belt testing New advances have been made that provide a more sophisticated application of belt monitoring, including the development of safety factor (SF) analysis based on NDT signal analysis This paper will grve an historical overview
2.
1.
A
Introduction
procedure used to obtain vital data for safety production based on belt damage or manufacturing quality There are three distinct phases required in the evaluation of belting condition in relation to the conveyor system Phase 1 is considered to be the data collection phase, Phase 2 is the anal-
Rg
factor
great deal of knowledge has been gained dunng the past 17 years on the subject of conveyor belts and their modes of degradation This new knowledge was made possible through techniques developed to monitor the reinforcement of conveyor
belts
In retrospect the science of belt nondestructive testing (NDT) was bom in Australia in 1979 with the patenting of a system that came to be known as the "cbm" or conveyor belt monitor The
Rg
Process used to
in a
USED BELT
NEW BELT
NDT Process
research of Harrison
[1,2]
the
resulted
in a series
of papers and
patent applications
on
new
technology
Extract damage Information
Once the concept that a belt could be tested by non-contact methods was demonstrated, it became an established method for testing belts worldwide The ramifications to the manufacin terms of quality assessment, and to the mine in terms of damage evaluation, have been quite profound Research contmues to discover new facts about belt and splice condition In
Variations
turer
Calibration
Calibration
Compute Stress
Concentrations at Problem Area
Phase 2
of
is
discussed
application of this research has been in belting safety factors at a damage or defect site This procedure was developed for steel cord belts as early as 1981 [3,4] No longer is it acceptable to simply measure the levels of damage in the belting, but rather the industry requires an evaluation of belting strength at the location of greatest conThe natural direction for
evaluation of
Prof Dr Alex Harrison President Scientific Solutions Inc Managng MemConveyor Technologies Ltd LLC 2200 Chambers Rd Unit J, Aurora.
, ,
Graphical Display
(^De-
SFf
[Measure
(^De
or
>
P/iase 3
ber
page 149
13
ysis of the data in terms of actual belting SF relative to the ongmal design value, and Phase 3 considers the ramifications of the
starting
In
or
stopping forces
on
the actual
belting SF value
the
at lo-
Transmitter
Receiver
Processor
cations of
an
damage
or
cord
plane defect
tions are
true
following
equaMagnetic Pocket
Break
(D
Mass
Steel Cord
*2
where =10
-
(2)
=
NDT
Signal
and
Signature
time
(fabric belt nominal) and SFq 6 67 (steel cord SFq belt), where /(., is the computed stress concentration factor at the damage site or at the irregularity in the reinforcement (usually /c, > 1 2) and /Cg is the ratio of the highest dynamic belt force Tpeak to the highest static belt tension 7"^
Based
ods at
on
OUTPUT
Breaks
Y
time
the
procedure outlined in Fig 1, computation of /c, in detail by Harrison in [7] Analytical meth-
Fig
Schematic of
system
(broken reinforcement) and at manufacturing (buckles) In other words, the factor /c, is directly related to the damage or defect magnitude as detected by non-contact NDT methods Application of this theory using computer generated stress fields is discussed in a later section
defect locations of this paper
the computation of /Cg is overstress in the belting, based
damage
3.2
In
Damage Monitoring
general, sensing systems similar to those shown in Fig 2 are used to test conveyor belts The system in Fig 2 has been developed to monitor corrosion and broken cables in steel cord belting without the need to magnetize the belt This technique has significant advantages over earlier monitoring systems in that belt magnetization or pre-conditioning is not required to remove spurious signals (magnetic pockets) from the belting (US Patent 4,864,233) Fig 3 shows typical raw data recorded from a test rig designed a 4 m length of belting The data was obtained from a system described in Fig 2 Full scale deflection of the signal that represents one broken cable depends on the sensor geomto simulate
Finally,
either
starting
or
directly related to the dynamic on the highest belt tension for stopping according to the equation
f
=
/ 7
max'
peak
(3)
in
which
kg
puter [8]
in
either directly measured or modeled on a comThe application of this method is also discussed later
is
the paper
3.
NDT
etry, as is the case with "cbm" systems Nevertheless, the monitoring system is highly immune to magnetization in the belting, making it an ideal testing system particularly when some of the
belting is magnetized and some is new and unmagnetised This system removes the complexities associated with magnetic conditioning and data interpretation
Some typical NDT signals of damage in a steel cord belt are illustrated in this paper Similar types of signal may be recorded
from fabric belt tests
3.1
Background
During Phase 1, the belt is tested by non-contact NDT methods Sensors available for testing steel reinforced belting include magnetic, eddy current, electromagnetic, x-ray and vibration sensor systems Sensors available for testing fabric belts inelude force transducers, electric field devices, vibration measurtest the
Fig 3
Outputs of
monitoring system
immune to
belting fields
ing systems and x-rays Each of these systems continuity of the belting reinforcement
are a
are
employed
to
There
developed over more recent years as alternatives to the original Conveyor Belt Monitoring system ("cbm") invented in Australia by Harrison in 1979 (US Patents 4,439,731) During 1990, an array sensor system was developed at The University of Newcastle, Australia These sensors are used by Conveyor Technologies Ltd (CTL) and TUNRA USA Inc to monitor steel cord
belts
an
eddy
cur-
system developed in Germany, a modified wire rope testing device (also developed in Germany) and a steel cord monitoring system developed in Canada that displays NDT data in graphical form on a computer screen Many of these alternative monitonng systems need to develop a track record in order to provide the
industry with the necessary confidence that the data being correctly interpreted
is
Clearly, there
belts
are a
can
Fabric belts
is in
testing
CTL
also be tested but in many cases the not cost effective The belt monitoring system used by
the USA
(BeltScanner)
the testing of cable belts, pipe belts, flexowalltype belts and belts with any physical shape
tions,
including
14
SOlidS
handling
Volume 16
Number 1
January/March 1996
Press
Baiting
Length
NOT
i->u__J,
I
Broken
Cords-^ I
Edge
at Press
Overlap
Direction of fabrication
Fig.
Fig.
4:
7:
NDT signals
showing deterioration
at
manufacturing
defect sites
Typical
effect
NDT belt
on
signals mistracking
faulty splice
snowrtg the
fects
Fig. 4 shows a record of a steel cord belt magnetic break signal, together with the tracking data, in a region of a faulty and failing splice. This data was collected with a system shown in Fig. 2. The splice exhibited considerable edge sag and mistracking, along with an irregular splice signature. Fig. 5 shows a steel cord belt with periodic damage that results from either rock spillage or ice lumps traveling around a pulley in the system.
displacements of some cables and reported for many years [9]. This type of departure from a flat plane of reinforcing cables is a defect that is responsible for cable breakdown over a period of time. A mechanism that describes the generation of these defects has been published [10].
are
The greatest problem with defects that involve cable or fabric layer displacements is reduced belt life and increased stress
lowering
just
3.3
inforcement in
as
the detection of
damage
to re-
a new commissioning scan anomaly that is related to belting cord plane signature with fringing magnetic fields every 30 ft, which happens to be the press length in manufacture. These ef-
the
7 shows the inter-relation between cord plane defects and resulting NDT signal when displaced cables fatigue and break [9]. This figure shows the general location of cable plane anomalies in relation to the press length. A similar process may
Fig.
occur in
iiiiiiiiiiii?ii-
1-
No. B
1
1
Fig.
5: 6:
NDT NDT
signals of
belt with
Fig.
signals for
belt with
manufacturing anomofies
at a press
length
h:.
Mi
rrtr
k
t:::
n
H
fl
I;..
:|!
n
tl:.
m
i
::' i
rj-|,
BB iBll iBSfl
Bj
-;:
i
,7Tnr"T!ilJlfir:
1
tt::
Ill
BE
I
11
T'rrllir?
HiS
::::
.
15
Volume 16
Number 1
January/March
1996
Stage 3
Fig
arms of Phase 1 in Fig 1 are completed from analysis perspective With regard to steel cord belting, the problems associated with cable displacement during the curing process are not restricted to one particular belt supplier To solve this problem the belt manufacturer needs to first be able to compute the magnitude of the cable pre-tension, based on time-dependent, thermally-induced strain during vulcanisation The general equations for determining a steel cord cable pretension necessary to prevent buckling are
developed to aid in the interpretation of splice NDT signatures [11, 12] This involves the computer generation of reference magnetic signatures of the particular splice lay-up or geometry Reference signatures are unique to each splice design Stage 1, stage 2 and stage 3 splice reference signatures for a particular splice lay-up pattern are shown in Fig 8 A BeltScanner monitonng system was used to measure these splices Fig 9 shows
some
P(K, A7",
a,
in
/_)
>
(4)
belts with stage 1, 2 and stage 3 signatures, respectively Departure from the ideal signature indicates either a small lay-up
difference
are in
or the existence of damage In addition, splices that the process of failing have distinctive changes in their NDT signatures Another use of this technology is in determining an
where
Fq
is
the initial
is
pre-tension
ding
covers, P
on a
the Euler
buckling
based
temperature
initial cable locked-in
an
unknown
on
signature matching
usually
place
4.
Phase 2
3.4
NDT of
Splices
As part of the NDT process outlined in Phase 1 testing, conveyor belt splices are also monitored because splices are a po-
tentially weak
Fig
9
link
in a
technology has
1 2 and 3
been
nondestructive^ tested, there was no begin analysis of the effect of damage and defects on the actual working stresses in a belt This problem was particularly relevant to the high tension steel cord belts because of the possibility of lowered safety factors (SF) to reduce capital costs
knowledge available
to
Measured NDT
splice signatures
of
typical stage
splices
As discussed
terms of
in
Fig 1,
belt
weak locations
in a
is
the natural step after the detection of to analyze their relative importance in
to
1991,
number of
papers were initiated from the above NDT research that mvestigated SF issues [13-17] A notable paper was published in 1990
"Safety Factor Calculations for High-Strength Inclined Belts on NDT Analysis" [16] This paper showed how stress concentration factors can be developed and used to generate computer-based tension distributions across the width of a belt at sites of damage or loss of reinforcement tension
on
based
Fig
10
46 cord
system
sisna T(i)
i a
Coda data AH 8
4
1 1
(fro
1 1 1
cord
1 1
2
1
1
>
1
1,1
II
46
Cords
per
Uidth
16
SIMS
handlin
Volume 16
Number 1
January/March 1996
tions used
TENSION RE-OtSTRIBimON
6 CORO BREAK IN A 96 CORD BELT
reinforcement and the rubber in the shear zone Analytical soluby Randall [18] for fabric belts have been developed
belt
apply to steel cord belts Fig 11 shows that when significant damage is detected, stress factors increase considerably in adjacent unbroken cables, and in some cases result in operating SF values that are close to unity
to
5.
Phase 3
Analysis
In conveyor
conveyor
is
design, the highest belt running tension along a generally used as the basis for setting the belt that a SFq of between 6 67 (steel cord belt) and 10
tensions based on these SF values
as
referred to
in
7^
in
earlier sections
Forces
value of
/Cj
is
(3) This
\MOTHOFBGLT(9n
7"^ need to be predicted so that the be used to further de-rate SF, according to Eq achieved by dynamic analysis of the conveyor to obtensions
in
tain the
highest
the belt
on
either
starting
or
stopis
ping Conveyor profile determines the type of situation that likely to produce high forces
Rg
11
Stress factors at
a site
of
During
1991
tion of more
a partition model was developed to allow prediccomplex stress patterns in a belt with damage A
All attempts should be made to reduce transient stresses in belts on starting or stopping [19] In braked downhill conveyors, for example, stopping stresses in the belt will most probably overshadow any starting forces Take-up type and location has a good deal of influence on dynamic stress amplitudes Certain
partition model allows the broken reinforcement to reside at any position across the belt The research was experimentally
tested
on 4
and 5
ply
fabric
belting [17]
Fig 10 shows the application of "Cord Stress Factor" (CSF) modeling to determine the amount of overstress and stress redistribution near reinforcement damage This example shows
the stress distribution
in a
types of conveyor profiles will generate problems with either high or low dynamic belt tensions on starting or stopping An assessment of each conveyor on a case-by-case basis is neeessary to property evaluate the dynamics of the drive and the belt as a mechanical system [20 24]
-
Assuming that there are dynamic forces above 7"^, then the dynamic analysis will permit the extraction of peak forces from
which
/Cj
and hence
a
SF2
are
calculated
Fig 10,
the CSF
is
computed
is
to be
/c,
means
SF,
6 67/2 464
27 This lowered
conveyor with a very small fall in elevation, driven at the tail and operated with a brake Braking stops the conveyor in about 8 seconds There are no booster drives, and
a
Fig
14 shows
SF does not allow for any additional stresses from transitions, dynamic forces and loading stresses
winch at station 6
is
locked
on
to and from a
concern
stockpile
power station
are:
on
Figs
a
bution both
and
along
points of
design
the amount of
pretension needed
belt depends
12
starting,
Fig
13
Fig
Compound breaks
are
in
Bg
12
Multiple
Break Tension
on a
Analysis
40 cord belt
5S 5SE
in
II II II
II
I I 1 I
II
II 11
I r
Mill 1 mi 1 mi 1 mi
1 IB 1 11
1 1 1 1 1 1 11 11 11
1 I 1I 11
j
i
11 11
1I 1 l
I!
II 'I 1 II
I
1 1 1 1 1 1 1
1 I 1 1 1
1 il 1 1 I
II Illll IHII
Illll Ulli Illll Illll
Width of Belt
1
1
17
jme
16
Number 1
January/March 1996
SOlidS
handling
Rating
=
2200 kN/n
Project:
Date:
tailflat
1353
2500 T/hr
11-28-1995
Temp *C:
Velocity
=3.50
m/s
263 kU
XVr = Tl = 103 kN
0.0203 0.0150
T2
28 kN
Hain Driue
Brake
Station 1 Power
=
TU
Station 6
0 kU
Fig
14.
Belt
profile
is 103 kN, the ^ tension rises from 28 kN to 190 kN during a stop. The arrow in Fig. 15 shows the tension 7 ^ used in the
age.
To address these concerns, more than a static tension analysis is required. The dynamic tensions resulting from starting may be modeled
analysis.
In this case,
an
overstress at
7g of
=
design
[25]
pre-tension
a
tension of 103 kN, is the basis of the SF calculation. The calculation produces a value of /^ 1.84.
needed to prevent drive slip on starting. Generally, controller would be recommended in this situation.
soft start
Suppose the belt parameters are similar to those described in Fig. 10, then the following de-rating of the belt is made:
complex. The tensions at the output of on stopping. Although the belting SF may be based on the highest 7^ running tension, braking can cause tensions in the belt to rise beyond predicted levels. Peak dynamic forces of this nature will further reduce belt SF particularly in areas of the belt that are damaged.
Stopping
can
be
more
Original
belt:
SFq SF^
SF
6.67
SF/2.464
2.7
peak dynamics:
SF^/ZCg
1.46.
Fig. 15 shows the 3D modeling of the tensions in the belt on stopping. From the data produced by the model, the peak
forces at the output of the drive (7g) rise from their static level of 103 kN to 190 kN on the second wave, approximately 6 seconds after shutdown. Since the
example illustrates the importance of the complete analysis of a belt SF when both damage and dynamic forces are present. The complete procedure illustrated by Fig. 1 is now completed, and shows that an analysis based on a system approach is required on a case by case basis.
"T,
or
tight
side
running
during
tension
6.
The
Conclusions
Fig. 15.
overstress
the stopping
importance of a systems approach to belt nondestructive testing has been described in this paper. The methodology developed over the past 15 years encompasses all known aspects of the problem of evaluating belting viability.
analysis of the ultimate belt SF has been monitoring methods for testing steel cord and fabric belts. Application of the monitoring technology in its own right has been beneficial to industry. Demand for this type of information has led to the development of alternative monitoring systems, however the experience in belt nondestructive testing application is usually essential. The use of belt nondestructive testing has been developed beyond the simple testing phase.
A
Stopping
Tensions
the
the
of
150000
^120000
g
t
"
Tail
T1
(sec)
question has been, "what does the damage monitoring system really mean in terms of belt reliability?" To address this question, research was initiated on safety factor (SF) analysis. Analytical tools have been developed and tested over many years, including software that permits the analysis of NDT data from any sensor system. The coupling of belt stress distribution analysis at damage sites and belt dynamic analysis methods, to the NDT problem, has resulted in a technology that answers the vital question regarding belt reliability.
detected
by
18
SOMS
luntfHnfl
Volume 16
Number 1
January/March 1996
References
[1]
Harrison, A.: New development in conveyor belt monitoring; Aust. Machinery & Production Eng., Vol. 32 (1979) No.
[19] Harrison, A.: Transient stresses in long conveyor belts; Proc. Symposium on Belt Conveying of Bulk Solids, Universrty of Newcastle, November, 1982, pp. 9.1-9.8.
[20] Harrison,
veyor
in con-
12, p. 17.
belts;
Mechanical
Engineering
Transactions,
[2]
Determining conveyor belt serviceability using signature analysis; Process Eng., Vol. 8 (1980) No. 6,
Harrison,
pp. 22-25.
A.:
[21] Harrison,
A.:
in
belts
[3] [4]
Harrison, A.: Developments in bulk handling research Australia; Aust. Coal Miner, November 1981, pp. 62-65. Harrison, A.: Trends
in
three wound rotor motors; bulk solids (1985) No. 6, pp. 1153-1157.
in
[22] Harrison,
A.: On the
appropriate
use
of
the
models for conveyor design; bulk solids (1988) No. 6, pp. 677-680.
dynamic handling
stress
Vol. 8
[5]
deterioration
Harrison, A.: A magnetic transducer for testing steel-cord in high-tensile conveyor belts; NDT Int., Vol. 18 (1985) No. 3, pp. 133-138.
new
[23] Harrison, A.: Modern design of belt conveyors in the context of stability boundaries and chaos; Philosophical Transactions Royal Society, London, Vol. 338, 1992, pp. 491502.
on
the
tional Conference
Bulk Materials
Storage, Handling
&
[7]
Harrison, A.: Performance of corded composites with and misaligned reinforcement; Proc. Inaugural Asia/Pacific Composites Institutes Conference, Adelaide.
damaged
[25] Harrison, A.: Simulation of conveyor dynamics; handling. Vol. 16 (1996) No. 1, pp. 33-36.
bulk solids
Aust. 1989.
[8]
namic
Harrison, A.: Future design of belt conveyors using dyanalysis; bulk solids handling Vol. 7 (1987) No. 3,
pp. 375-379.
[9]
in
steel cord
pp. 839-
belting;
842.
bulk solids
handling
Vol. 11
(1991) No. 4,
[10] Kasper,
measurement
method for NDT of steel cord belt splices; Proceedings 12th World Conference on NDT, Amsterdam. 1989. pp. 330-335.
RD
(TRANSPORTGUMMI GmbH
Made
in
[12] Harrison,
signature
to monitor belt
Germany
[13] Harrison, A.: New techniques for monitoring defects in underground steel cord belts; 21st International Conference of Safety in Mines Research Institutes, Sydney, Austraha, 21-25 Oct. 1985, pp. 213-217.
[14] Harrison,
with
edge
A.: A failure model for corded composite plates fractures; J. Strain Analysis, Vol. 22 (1987) No.1,
pp. 49-53.
[15] Harrison,
Vol. 8
cord plane defects and inlaid repairs; bulk solids (1988) No. 4, pp. 443-446. A.:
handling
[16] Harrison,
and
belts based
Safety factor calculations for high-strength NDT signal analysis, Proc. Coal Handling Utilization Conference, Sydney, June 19-21, 1990,
on
Rudolstdter Strae 23
D-07422 Bad
pp. 289-295.
Blankenburg
[17] Harrison,
site
in
A.: Stress concentration prediction at a fracture composite bimatenal plates under axial load; Proceedmgs International Conference on Fracture of Engineenng Materials and Structures, Singapore, 6-8 August,
Phone:
Fax:
(004936741)5302
(004936741)5440
[18] Randall,
in
splices
in
Engineering Transactions,
Reader Service Card No. 7
19