Portable Hydraulic Banding Machine for Recapping Wedge-Type Rope Cappel – DGMS Guidelines + 25 MCQs

🧾 DETAILED NOTES

1️⃣ Introduction

Wedge-type rope cappels are used for connecting winding ropes to cages, skips, counterweights, and balance ropes. During periodic inspection, recapping becomes necessary to ensure rope integrity, proper seating of strands, safe load transfer, and compliance with DGMS standards. A portable hydraulic banding machine ensures uniform and safe recapping of rope cappels at the mine site.

2️⃣ What is a Wedge-Type Rope Cappel?

A rope cappel is a mechanical socket where rope strands are inserted with a wedge to hold the rope by friction and compression. Advantages: Easy installation, High tensile efficiency, DGMS-approved design, Suitable for vertical shaft winders.

3️⃣ Why Recapping is Needed?

Recapping is required due to rope elongation, wear & tear near the cappel region, strand displacement, inspection defects, and to meet DGMS statutory recapping intervals. Failure to re-cap properly may lead to rope slip, cage/skip fall, or catastrophic winder accidents.

4️⃣ Portable Hydraulic Banding Machine – Purpose

This machine is used to apply uniform, controlled compression bands around the rope near the cappel. Benefits: High accuracy, Eliminates manual hammering, Reduces risk of rope damage, Ensures perfect wedge locking, Fast, safe operation, and DGMS compliance.

5️⃣ Recapping Procedure (DGMS-Aligned)

Preparation: De-tension the rope, Clean rope strands, Inspect for internal/external wear, Remove old bands.
Insert Rope into Cappel: Open wedge, Straighten strands, Lubricate with approved compound, Insert rope fully & seat wedge.
Hydraulic Band Application: Select required band size, Position the band correctly, Apply hydraulic pressure gradually, Maintain uniform compression.
Final Checks: Check wedge seating, Ensure no strand crossing, Ultrasonic or magnetic testing (as applicable), Conduct load test, Record in winder logbook.

6️⃣ Statutory Requirements

Regulation / Rule	Description
CMR 2017 – Reg. 99, 101, 102	Winding equipment maintenance, rope examination
MMR 1961 – Reg. 86, 87	Man winding safety, cappel examination
DGMS Tech Circulars	Rope recapping intervals, testing procedure
IS: 3973	Rope cappel specifications

7️⃣ Safety Precautions

Only trained personnel must operate hydraulic banding machine.
Rope tension must be fully released.
Wear PPE: gloves, face shield, safety shoes.
Maintain safe distance during band compression.
Check hydraulic fluid level before use.
Ensure wedge does NOT slip under compression.
Record every recapping in the statutory register.

8️⃣ Advantages of Using Hydraulic Banding Machine

Prevents strand damage
Reduces manual error
Provides uniform force
Enhances reliability of the cappel joint
Saves time & manpower
Reduces failure risks

⚙️ QUICK ONE-LINERS (Revision Points)

Recapping ensures proper load transfer.
Wedge-type cappel grips rope by friction & wedging.
Hydraulic banding gives uniform compression.
DGMS requires periodic rope recapping.
Poor recapping may cause rope slip accidents.
Bands must conform to IS standards.
Winder logbooks must record recapping.
Only trained persons should operate the machine.
PPE mandatory during banding.
Rope strands must NOT cross during insertion.

🧠 DESCRIPTIVE Q&A

Q. Explain the use of a portable hydraulic banding machine in recapping wedge-type rope cappels in mines.

Answer:
A portable hydraulic banding machine is used to apply uniform compression bands on winding ropes during recapping of wedge-type rope cappels. After the rope is cleaned and inserted into the cappel, hydraulic pressure is gradually applied to fit metallic bands securely around the rope, ensuring proper wedge seating and preventing slippage. This method minimizes manual errors, avoids strand damage, and complies with DGMS standards. The process enhances safety and reliability of winding operations in shafts.

🧮 25 MCQs (Dynamic Answers – 5 Options Each)

Q1. Wedge-type rope cappel is used for:

Solution: A rope cappel is the standard device used to terminate a wire rope and attach it to a load (cage/skip).

Q2. Purpose of recapping:

Solution: Recapping removes the fatigued end of the rope and re-establishes a secure connection.

Q3. Hydraulic banding provides:

Solution: The primary advantage of hydraulic banding over manual methods is the application of consistent, uniform pressure.

Q4. Rope cappel failures may cause:

Solution: Failure of the cappel disconnects the load from the rope, leading to a catastrophic cage fall.

Q5. Rope strands must be:

Solution: Strands must be straightened and cleaned before insertion to ensure proper wedging action.

Q6. Regulating authority:

Solution: The Directorate General of Mines Safety (DGMS) regulates all safety aspects of mining in India.

Q7. Banding machine must be operated by:

Solution: Only personnel trained in the specific operation and safety protocols of the machine should use it.

Q8. Which regulation covers rope maintenance?

Solution: The Coal Mines Regulations, 2017 (specifically Reg 120 onwards) cover rope maintenance.

Q9. After recapping, rope must be:

Solution: A proof load test is mandatory to verify the integrity of the new capping before regular use.

Q10. Hydraulic pressure must be applied:

Solution: Gradual application ensures the bands seat correctly without damaging the rope or cappel.

Q11. Wedge grip depends on:

Solution: The wedge principle relies on friction between the rope, wedge, and cappel body to hold the load.

Q12. Recapping interval decided by:

Solution: DGMS regulations specify the maximum time interval allowed between recappings.

Q13. Rope inspection includes:

Solution: NDT methods like magnetic or ultrasonic testing are used to inspect ropes for internal flaws.

Q14. Cappel must comply with:

Solution: Indian Standards (IS 3973) govern the specifications and testing of rope cappels.

Q15. Hydraulic band failures may cause:

Solution: If the bands are not tight, the wedges may not seat properly, leading to the rope slipping out of the cappel.

Q16. Before banding, rope must be:

Solution: The rope end must be thoroughly cleaned to ensure good contact and proper inspection before recapping.

Q17. Wedge seating must be checked for:

Solution: Correct and uniform seating of the wedges is critical for the cappel to function safely.

Q18. Hydraulic machine reduces:

Solution: By automating the pressure application, the machine removes the variability and potential errors of manual hammering.

Q19. Recapping recorded in:

Solution: All maintenance activities on the winder, including recapping, must be recorded in the statutory logbook.

Q20. Strand crossing must be:

Solution: Crossed strands can create stress points and reduce the strength of the rope connection.

Q21. Hydraulic machine works on:

Solution: It utilizes hydraulic fluid pressure to generate the force needed for banding.

Q22. Rope cappel connects rope to:

Solution: The primary function is to connect the winding rope to the conveyance (cage or skip).

Q23. After recapping, check:

Solution: A load test is a mandatory safety check before the rope is put back into regular service.

Q24. Rope recapping ensures:

Solution: The primary purpose is to maintain the safety integrity of the winding system.

Q25. Major reason for recapping:

Solution: Wear, fatigue, and statutory time limits are the main drivers for recapping.

🔗 INTERNAL LINKS

Related Topic	Read More On...
Rope Safety	Slack Rope & Rope Slip Protection Guide
Man-Winding	Pit Bottom Buffer Requirements in Man-winding Shafts
DGMS Circulars	DGMS Tech Circulars & Guidelines
Mechanical Safety	Appointment of Engineers for Machinery Safety

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