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Eddy Current Testing of Rotary Processing Equipment

Armed with Ultron's latest Eddy Current probe design, two technicians, and partial removal of the kiln/mill gear housing, YOU can have your gear set examined completely while cooling down or firing up. Problems are eliminated with the refractory company because Ultron performs the inspection before their arrival or after their departure.

Ultron's crew will remove any excess lube in the root of the gear that may build up due to the mesh. Even though Eddy Current will locate a crack through lubrication up to 1/4" thick, we can increase the sensitivity and reduce the inspection time by removing the excess. We will also scrape and examine both side faces, to insure against over the edge cracking (again with a specially made probe to shield false edge interference), and to mark the gear for references and future examinations.

Eddy Current testing is not only used on cement kilns, but we can also look at your ball mill, coal mill, and raw mill during the same outage. If you have the maintenance personnel remove one section of cover to provide access (ladder, man lift, scaffolding, overhead safety ropes, etc...), we can do the rest.

How about an example, using the best case senario; Ultron has a client in such a remote section of the world it takes two days of travel each way. The second day of travel is by charter only. This particular client has seven ball mills from 11' to 23' in diameter. The client previously completed examinations by using four men during four days to partially exam two gear sets. Three years ago Ultron was invited to send two men to prove our Eddy Current testing technology. The client was not ready the first day. We completed one gear set the second day, 100%. We completed a second gear set the third day, then had to remain on site the fourth day due to the charter flight schedule. This past year we sent a four man crew and during the four day window we completed Eddy Current Testing on all seven gears sets 100%, had an exit meeting, and left the preliminary report.

I know I get off track a little, but I love that story. Disclaimer: This client has an excellent maintenance program and personnel. Ultron didn't find any major problems to be concerned about, and they can rest easier knowing the condition of all their gear sets because of Eddy Current testing performed with minimal down time.

Rotary processing covers a lot more than just the cement industry. Rest assured, we have not forgotten about anyone. Our clients also include aluminum and steel rolling mills, gold, silver, and phosphate industry rotary processing equipment.

About Eddy Current Testing

Our two man crew is its own safety department within yours.

Maintenance will need to remove cover(s) to give us access to the gear. The use of a dedicated maintenance personnel is advised due to plant safety procedures.

Once you have cooled enough to put the kiln on the inch/auxillary drive, Ultron's crew can begin the Eddy Current testing on the gear system.

All we need is solvent to verify the cracks. A step ladder, rags and brake cleaner are also appreciated.

No supervision is needed. We also have our own MSHA ID number, (with training in parts 46 & 48).

Our personnel will leave a preliminary report upon completion. We offer one of the finest final reports which includes a summary, conclusion, and information from our Mechanical Engineer who will interface with the OEM engineers to give you the best resources possible.

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