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Usage of Portable Hydraulic Banding Machine for Recapping Wedge Type Rope Cappel – DGMS Guidelines & 25 MCQs

Usage of Portable Hydraulic Banding Machine for Recapping Wedge Type Rope Cappel – DGMS Guidelines & 25 MCQs

🧾 DETAILED NOTES

1️⃣ Introduction

Rope cappels are critical components of mine hoisting systems, connecting the winding rope to the cage or skip. The wedge type rope cappel is widely used due to its simplicity and efficiency. However, periodic recapping (replacement of the cappel on the rope) is essential to prevent slippage and failure. The use of a portable hydraulic banding machine has greatly improved the safety and precision of this operation, reducing manual strain and risk.

2️⃣ DGMS Safety Concern

DGMS has reported several hoisting accidents due to improper rope capping or defective cappels. Manual hammering or improper socketing often leads to rope damage or incorrect grip. Hence, DGMS recommends mechanical or hydraulic banding methods to ensure uniform pressure and safe recapping of wedge type rope cappels.

3️⃣ Legal Framework

Reference Description
CMR 2017 – Regulation 120 Examination and maintenance of winding ropes.
CMR 2017 – Regulation 121 Capping and recapping of winding ropes.
The Mines Act, 1952 – Sec. 23 Safety of persons employed.
DGMS Circular (Tech.) No. 06/2018 Safe practices for rope capping and testing.
DGMS Circular (Mech.) No. 04/2016 Use of mechanical aids in capping operations.

4️⃣ Objective

The purpose of using a portable hydraulic banding machine is to:

  • Ensure uniform pressure during recapping.
  • Avoid manual hammering and rope strand damage.
  • Improve safety and efficiency in shaft maintenance.
  • Meet DGMS requirements for safe rope termination.

5️⃣ Construction of Wedge Type Rope Cappel

A wedge type cappel consists of: A cappel body with conical recess; Two wedges that grip the rope strands; Retaining band or collar applied using hydraulic machine; Thimble and shackle for attachment to the cage or skip. When properly recapped, the rope load is transmitted through friction between the wedges and rope strands.

6️⃣ Use of Portable Hydraulic Banding Machine

⚙️ Step-by-Step Procedure:

  1. Clean and inspect rope end for broken wires or corrosion.
  2. Insert rope end into the cappel body and position wedges.
  3. Align the wedges uniformly in the conical slot.
  4. Place portable hydraulic banding machine around the cappel collar.
  5. Apply hydraulic pressure gradually to tighten the retaining band.
  6. Ensure no rope twist or slack during banding.
  7. Verify band tightness and alignment after operation.
  8. Conduct a load test before using in service.

7️⃣ Advantages of Hydraulic Banding Machine

  • Eliminates manual hammering, reducing risk of rope damage.
  • Ensures uniform and controlled band tension.
  • Portable and easy to operate underground.
  • Reduces capping time and labor effort.
  • Provides higher reliability and safety compliance.

8️⃣ DGMS Guidelines for Recapping

  • Recapping must be performed under supervision of a competent mechanical engineer.
  • Only DGMS-approved machines should be used.
  • Rope ends must be examined for broken wires as per Reg. 120(6).
  • Hydraulic banding pressure must be recorded and logged.
  • The cappel must be load tested to 1.25 times working load before re-use.
  • Maintain recapping records in the Rope History Register.

⚙️ QUICK ONE-LINERS (Revision Points)

  • Rope cappel connects rope to cage or skip.
  • DGMS Circular 06/2018 → Rope capping & testing safety.
  • Portable hydraulic banding machine ensures uniform pressure.
  • Avoids manual hammering and strand damage.
  • Load test = 1.25 × working load.
  • Record in Rope History Register.
  • Reg. 120 & 121 → Rope maintenance & capping.
  • Hydraulic banding improves safety and precision.
  • Must be done under supervision of competent engineer.
  • Use only DGMS-approved banding equipment.

🧩 DESCRIPTIVE MODEL QUESTION & ANSWER

Q. Explain the usage and advantages of a portable hydraulic banding machine for recapping wedge type rope cappels.

Answer:
A portable hydraulic banding machine is used to apply controlled hydraulic pressure during recapping of wedge type rope cappels in mine hoisting systems. It replaces manual hammering, ensuring uniform band tension and preventing rope damage. The process involves placing wedges in the cappel body, positioning the hydraulic band, and applying pressure gradually until secure. Advantages include: Uniform grip and alignment; Increased safety and reduced time; Compliance with DGMS Circular 06/2018 and CMR 2017 Reg. 120–121. Thus, hydraulic banding ensures reliability and safety in hoisting operations.

🧮 25 DGMS-Based MCQs

Q1. DGMS Circular related to rope capping and recapping:

Solution: DGMS (Tech.) Circular No. 06/2018 provides the most recent detailed guidelines on safe rope capping practices.

Q2. Regulation for rope examination:

Solution: Regulation 120 of CMR 2017 details the examination and maintenance requirements for winding ropes.

Q3. Rope cappel connects:

Solution: The cappel is the mechanical device that terminates the winding rope and attaches it to the cage or skip.

Q4. Portable hydraulic banding machine used for:

Solution: This specialized tool is used to apply the retaining band on a wedge type cappel under controlled hydraulic pressure.

Q5. Load test after recapping should be:

Solution: A proof load test, typically 1.25 times the maximum static load, is often required to verify the integrity of the new capping.

Q6. Main advantage of hydraulic banding:

Solution: Unlike manual hammering, the hydraulic machine applies a consistent and measurable pressure, ensuring a secure and uniform grip.

Q7. Rope history record maintained by:

Solution: The Mine Manager is ultimately responsible, though the Engineer maintains the Rope History Register (Form R-3 / Logbook).

Q8. Wedge cappel type commonly used in:

Solution: Wedge type cappels are a standard method for terminating (capping) winding ropes.

Q9. Cappel load test conducted by:

Solution: Load testing of critical equipment must be supervised or conducted by a competent engineer.

Q10. DGMS Circular 04/2016 deals with:

Solution: This circular emphasized using mechanical aids (like hydraulic banders) to improve safety during capping.

Q11. Manual hammering causes:

Solution: Manual hammering is imprecise and can cause damage to the rope strands or cappel components.

Q12. Cappel wedges transmit:

Solution: The wedges grip the rope, transmitting the load from the rope to the cappel body and then to the cage.

Q13. Portable machine is:

Solution: "Portable" implies it is designed to be mobile and can be taken to the job site (e.g., pit bottom).

Q14. DGMS stands for:

Solution: DGMS is the Directorate General of Mines Safety.

Q15. Hydraulic pressure ensures:

Solution: The key benefit of hydraulics is applying a controlled, uniform pressure on the retaining band.

Q16. Recapping frequency depends on:

Solution: Recapping is done based on statutory requirements (e.g., every 6 months) or earlier if rope condition (broken wires, corrosion) dictates it.

Q17. Rope test frequency:

Solution: Winding ropes must be tested (recapped and a sample tested) at intervals not exceeding six months (CMR 121).

Q18. Load test required before:

Solution: A proof load test is required after installation or recapping, before commissioning the rope for regular use.

Q19. Broken wires in rope checked under:

Solution: Regulation 120(6) of CMR 2017 specifies the examination of ropes, including checking for broken wires.

Q20. Hydraulic banding machine operates on:

Solution: The machine is hydraulic, meaning it uses high-pressure fluid to generate force.

Q21. Portable banding machine reduces:

Solution: It replaces the physically demanding and strenuous process of manual hammering.

Q22. DGMS recommends load test before:

Solution: The integrity of the new capping must be verified by a load test before it is put into service.

Q23. Recapping done under:

Solution: Recapping is a safety-critical statutory job that must be supervised by a competent engineer.

Q24. DGMS Circular 06/2018 focuses on:

Solution: This circular provides modern, updated guidelines on safe practices for rope capping and testing.

Q25. Main purpose of recapping:

Solution: Recapping is done to remove the rope end that suffers the most fatigue and to ensure the connection remains secure, preventing slippage or failure.

🔗 INTERNAL LINKS

Related Topic Read More On...
Mine Rescue Mines Rescue Rules, 1985 - Notes & MCQs
CMR 2017 CMR 2017 Part 2 - Working & Supervision Rules
MMR 1961 Metalliferous Mines Regulations 1961 - Chapter 1
DGMS Circulars DGMS Tech Circular No. 02 of 2020

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