INVESTIGATION OF LOADING CONDITIONSOF STACKER RECLAIMER COMPONENTS

PROJECT OVERVIEWA Finite Element Analysis (FEA) model of the NCIG stacker reclaimers was created to perform a fatigue analysis on the machines to predict failure and outline future service required for the machines.

The finite element model highlights parts of the machine that experience high load during its service life, and these ‘hot spot’ areas are then investigated further to determine any maintenance required to prevent failure.

The predicted time until failure is greatly affected by the loads that are used for the model. Australian Standards including AS4324.1-2017 and AS4100-1998 were originally used for the load calculations, however these loads are conservative and predict machine failure much earlier than when a machine will fail in practice. In this case, some components were predicted to have already failed.

CLIENT Newcastle Coal Infrastructure Group (NCIG)

LOCATION Newcastle, NSW

PROJECTNCIG is the owner and operator of one of Australia’s major coal export terminals. The site is responsible for the transfer of coal from train unloading facilities to ships.

Verico was engaged to install accelerometers, strain gauges and a camera to investigate the in-service loading conditions of stacker reclaimer components.

The actual loads experienced by the stacker reclaimers can be measured directly by strain gauges, accelerometers and operation data such as motor current and torque, belt weigher data and wind measurement.

Verico was engaged to install accelerometers, strain gauges and a camera to measure the actual loads of the stacker reclaimers to better predict failure time-frames and outline preventative maintenance activities required.

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Installation of strain gauge

REMOTE MONITORINGThe data was able to be remotely monitored from Verico’s office, which allowed Verico to ensure that the data was being recorded properly, and to troubleshoot any problems.

The camera footage was linked to the strain gauge and acceleration data, which assisted greatly in associating the movements of the machine to the data captured.

CHALLENGESA challenge for the project was determining the best accelerometer to detect the low levels of acceleration that a stacker reclaimer experiences from its long travel, slewing and luffing movements, while isolating the normal levels of vibration not associated with the major structural movements. In addition to this, there were some wireless transmission problems caused by the amount of steel in the structure. Some level of development was required in order to configure the appropriate accelerometer.

Accelerometer testing was conducted, with an expected acceleration of approximately 0.1 m/s² for both long travel and slewing movements (separately). During the test, the machine was not stacking or reclaiming, it was operated just for the testing, and the results aligned well with the expected magnitude of 0.1 m/s².

PROJECT OUTCOMEThe data capture assisted in the measurement of the actual loads experienced by the stacker reclaimer, rather than conservative theoretical loads. By measuring the strains and acceleration in critical locations, fatigue failure predictions were more accurate and realistic.

INVESTIGATION OF LOADING CONDITIONSOF STACKER RECLAIMER COMPONENTS

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EWP access to install strain gauges

Screenshot of remote monitoring screen