Objectives

The primary objective of this tender is to appoint a service provider to undertake research project CoE 210502, focusing on the assessment and review of winder rope discard criteria, testing procedures, and condition assessment protocols. The research aims to update and improve existing standards, develop new testing and inspection methodologies, and enhance inspector training modules to ensure safer and more reliable operation of winder ropes in mining environments.

Scope

The scope of work includes:

• Assessment of current performance, operation, testing, maintenance, and discard criteria of winder ropes in the mining industry.
• Identification of limitations in existing protocols and proposing improvements aligned with international standards and benchmarked against SANS 10293.
• Collection and tensile testing of rope samples at discard points to validate or refine discard criteria for various rope constructions (triangular, ribbon, compact strand).
• Comparison of measured strengths with operational tension data to determine safety factors.
• Development of updated training modules for rope inspectors based on research findings.
• Identification of gaps in current testing protocols, especially non-destructive evaluation tools like magnetic flux leakage and ultrasonic testing.
• Verification and quantification of real-world performance data to update standards and testing procedures.

Technical Requirements

The technical requirements include:

• Conducting comprehensive literature reviews and current limitations analysis.
• Proposing revised discard criteria for diameter reductions due to plastic deformation and abrasive wear, broken wires, and other failure modes.
• Testing samples of different rope types and configurations to establish safety factors.
• Benchmarking against international standards and updating testing and inspection protocols accordingly.
• Developing and validating non-destructive testing protocols, including calibration and standardization of MRT and other NDE tools.
• Creating modern, aligned inspector training modules incorporating new diagnostic technologies and failure modes.
• Facilitating stakeholder workshops to discuss preliminary findings and gather feedback.

Skills Requirements

The successful service provider must demonstrate:

• At least 5 years of experience in applied research or consulting related to winder rope condition assessment and testing in the mining sector.
• Expertise in mechanical engineering, specifically in steel wire rope behavior, fatigue, and failure analysis.
• Proven experience in developing and validating non-destructive testing protocols and standards.
• Capability to conduct tensile testing and laboratory assessments of rope samples.
• Experience in training development, especially for technical inspectors in the mining industry.
• Strong project management skills to deliver comprehensive reports, training modules, and protocols within the 18-month timeframe.
• Ability to collaborate with industry stakeholders, suppliers, and regulatory bodies to benchmark and align standards.