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Ultrasonic Testing for the Mining Industry

A dragline can pose many unique situations that no national inspection code will cover. Most dragline components are very large. Many codes even American Welding Society (AWS) specification D1.1, do not cover components for thicknesses greater than 12 inches. When you need to look at a swing shaft the thickness lies in the neighborhood of 21 inches in diameter. Let's go one step farther and say the best way to inspect this shaft is to have it rotating. We can actually find a smaller crack during operation than we can when the dragline is idle. Ultron is using angle beam (shear wave) up to 50 inches of sound path, and we can still see a crack about as small as an inch long. This particular inspection alone can save you in maintenance costs because we are looking below the revolving frame and under the bearing area without having to take the swing motor apart.

Since a code does not cover many of these dragline parts, it takes thinking outside the box and very intense training of personnel. Due to the geometry of dragline parts and unique situations for these parts, standard methods and angles do not work. Ultron's combined experience and knowledge allows us to work around these difficulties.

When you need to lay a Bucyrus Erie boom on the ground for maintenance, it is very important to look under all the lacing clusters for cracks. Standard Ultrasonic Testing allows three legs of bounce, or one and one half "V" paths. Ultron can detect cracks using up to fourteen legs, or seven full "V" paths, and still locate the crack within a sixteenth of an inch. You have to have knowledge of where something will fail, how the part is designed, and the Ultrasonic signatures of all nonrelevent indications due to lacing pipe welding. Ultron is one of the innovators of this technology and will help any client in any way possible.

We have not even begun to cover underground mining and using Ultrasonic testing on longwall mining equipment. Longwall shield components are beginning to fail due to operational duty cycles, fatigue, and corrosion. When you pull a longwall shield from one seam to move to another, do you want to find out the shield has a major crack in it after it is placed in its new position? Ultron has already started the first of the inspections that are being performed on longwall shields. Some of the bores can be examined in situ and you will know which shields to replace during your next move.

Ultron has its own MSHA ID number and you are invited to check our safety record. The Ultrasonic Testing equipment we use underground is approved by MSHA.

What you can expect from Ultrasonic Testing

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

We have all of our safety equipment required, including our own harnesses and lanyards. We would need SCSR training for your particular underground mine.

Pull the covers on the hoist and drag spiders.

Provide access to all areas (ladders, manlifts....)

All we need is solvent to verify the cracks for you. A step ladder and rags would be appreciated.

Our personnel will leave a report upon completion.

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