Improving Surface Mine Profitability with Phased Array Ultrasonics
Results of a year analyzing the use of Phased Array in the Mining industry.
Nicholas Bublitz Olympus Scientific Solutions Americas
Abbreviated Abstract and Scope
• ~9 years working mainly with Phased Array and Tofd
• Business Development Project- Mining Industry
• 2 years spent visiting mines and working on applications– ~1 year of actual field work
• Significant improvements to inspection found
• Focused at major surface coal locations
Mining Issues-What I learned
• $$$ of downtime
• Parts availability
• Limited downtime for inspection
• Limited inspectors
• Lack of procedures
• Thick and complicated
• Culture of SAFETY
Also very dirty….
Applications in Heavy Equipment
• Draglines, Shovels, and Other
• Fatigue cracks, repairs
• Majority– Shafts and pins
– Bores and lugs
– “other”
Dragline-Where we are Using or Working to use Phased Array
• Boom anchors, lugs, links and pins
• Mast anchors, lugs, links and pins
• Back leg anchors, lugs, links and pins
• Main suspension pins, attachment plates
• Intermediate suspension pins, attachment
plates
• Swing Shafts
• Boom point shaft
• “Sticks”
• Propel-Main shafts-Intermediate shafts,
Stabilizer Arms, Lifting hooks
• Fairlead Pins
• Hoist and Drag Drum Stub Shafts
• Drum Split line bolts
• Drum to spider bolts
• Hoist and Drag Intermediate Shafts
• Center Pin
• House Rollers
Conventional Ultrasound Issues
• Lack of access for full coverage with a single angle
• Limited in how it can be applied
• Difficult to decipher geometrical reflections from the parts
• Heavy reliance on skilled operator
• Lack of permanent record and data
• Limited detection/characterization especially in situ
Phased Array• Multiple angles or rastering
• Imaging/data
• Flexible/Adaptable
• Fast
• Affordable
• Simplified and accepted
• Conv. Flaw Detection comparison=confidence
Swing Shafts as Illustration of Issues• Issues
– Access
– Off the shelf angles
– Geometry
– Mode conversion
– Off angle cracks (“winders)
– Access
– Diameter/Thickness
Swings Shafts as Illustration of Benefit
• Identify and Reduce geometry
• Change angles on the spot on defects
• Manual or encoded for monitoring
Swings Shafts as Illustration of Benefit
• Reliable and repeatable
• Outperformed: Sized closer to
actual size
• Permanent records
Typical Recommended Equipment List
• Small phased array unit (manual and encoded capable) (OmniScan SX used for study)– Portable– Low cost– User Friendly
• Scan Design Software to develop inspection (ES BeamTool used for study)– Import drawing– Draw complex parts
• Optional post analysis software (OmniPC used for study)– Encoded data– View / share/report on PC
• Phased Array Probe and wedge (2.25L60-60X10-CA14-SPEC/ SA14-N55S used for study)
• Optional Encoder or Scanner (Mini Wheel and ChainScanner used for study)
Results of Implementations of Phased Array
• Converting almost all ultrasonics to phased array
• Immediate Improved results in detection, characterization and sizing. Shaft cracks are winding in nature.
• Faster and more reliable
• Expansion into more inspections with ultrasound
• More communicable to others who needed to do repairs
• Increased safety
Looking Ahead: Advanced Probe Technologies• CCEV Probes
– Curved in passive axis= better length
sizing
• Lateral Sweeping– Fixed angle, sweep side to side– Only requires wedge change
• Dual Linear Arrays– 2 common phased arrays probes
– Roof angle
– Sweep side to side– Limited by wedge
• Dual Matrix Arrays– Increased focus
– side sweeping– No real limit by wedge Limited
to wedge (mechanical)
Thank you!
For more information on Olympus Phased Array Ultrasonics:
www.olympus-ims.com/en/phasedarray