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Ultrasonic Testing for Rotary Processing

Ultron is a non destructive testing service company specializing in Ultrasonic Testing. Our primary concern is heavy industrial operators. We provide useful information with limited down time and dismantling. Decisions are only as good as the information provided those making the decisions. With rising costs and fewer personnel, information is very critical in preventing a catastrophic failure. More work has to be done by outside contractors. The need exists for a company to provide certified specialists having a Mechanical Engineer to communicate with the OEM's. The data collected by the field specialists, coupled with information from your OEM, provides the best report possible. The final report can be as simple as what the inspectors leave on site, or very in depth including a summary, conclusion, and information for our clients to determine what should be done.

Ultron will work to provide the inspection services you request. Ultron has produced more than 200 innovative techniques for the rotary processing and mining industries. Our concern in this section is to discuss rotary processing. May we begin with rotary kilns? When a crack is located on the kiln shell and the refractory brick is not removed from the back side of the weld, the only way to examine the integrity of the weld is with Ultrasonic Testing. The inspector has to know what questions to ask (were backing strips used, what welding procedure was used, did a replacement piece get installed, and is there a transition) to give you the best examination possible. Ultron will gather this information, will interface with the other contractors, and try not to increase your stress level.

Let's talk a little about the cement kiln tires. More information is being gained as more inspections are being completed. You could have spalling occurring just under the surface. How about cracks along the side face? What is the configuration of the crack profile of the tire? Did anyone ever tell you about cracks originating from the ID in the center of the tire? Think about how much dirt and rock slide around the tire between the alignment wedges and cause wall thinning. New research shows that a crack in a tire will fail more rapidly due to the environment of its operation. Tires with more than 20 years of operational life are susceptable to sudden ductle failure. You do not have the time to keep up with everything under your responsibility. Ultron can help because we have information coming in from our inspections throughout the country, we see more failures, and we locate more problems because of our specialization.

We can not talk about tires without discussing trunnion shafts. Trunnion shafts pose a very specialized examination, and no school in the United States teaches this inspection procedure. Cracks usually occur just inside the trunnion/roller junction (an area unseen by the naked eye). How do you find problems in a shaft with increasing diameters, and cracking from behind the junction? One has to work outside the normally accepted Ultrasonic Testing parameters. All shafts have varying diameters, and there may already be a three inch deep crack that could be a third of the way around the diameter before normal procedures will see it. Ultron's procedures work around these limitations.

Following is a sample list of shafts we are currently examining: Raw mill pinion and fan, bucket elevator, coal mill pinion, cooler fan, clinker breaker, and etc....

About what you can expect from Ultrasonic Testing

Our two man crew and its our own safety department within yours.

Maintenance will need to remove cover(s) to give us access to the shafts.

Access will need to be provided to inspect as much of the tires as possible. Safety cables will need to be in place.

All we need is solvent to verify the cracks for the final report. A step ladder and rags are also appreciated.

No supervision is needed. We also have our own MSHA ID number.

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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