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The surface mining of materials
like coal and other resources

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require a synergy between

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a multitude of mobile and
stationary equipment.

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From removing overburden
with draglines,

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loading haul trucks with shovels

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and all the processing, sorting and
conveyance equipment involved

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surface mining companies require the
right piece of equipment

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to be functional when they need it

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to meet production demands.

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Safety is priority number one
in the mining industry.

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The sheer size and close
work proximities

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of all this equipment make
this mandatory.

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All equipment must be closely
monitored for safe operations.

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Not having cracked or otherwise
compromised equipment parts

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is a crucial part of a safe operation.

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The falling of a “boom”
from a large dragline

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can cost millions of dollars even
without human injury.

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These costs can be incurred
from repair,

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replacement, investigation,

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down time and lost production.

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The loss of a single haul truck

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can slow production rates
significantly

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since they carry from 40 to 100
tons of product per load.

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Repair services and parts for
such massive vehicles

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is costly and time consuming
so early detection

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and monitoring of potential problems

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in all equipment is crucial.

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Mining companies worldwide,
like most industries,

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utilize non-destructive testing (NDT)
techniques and instruments

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to ensure safe and reliable
operation of their equipment.

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Many hire outside testing services,

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but many perform the inspections
with their own personnel.

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Stringent NDT testing on
mobile equipment

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is essential as these vehicles
are usually very large,

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under massive stresses

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and interact around other mobile
equipment operators

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and support personnel.

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Advancement in the core NDT technology

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of industrial ultrasound have
led to improved inspections

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and therefore increased
productivity and safety

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in surface mine operations.

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The improved ease of use,

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reduced cost and increased
industry wide acceptance

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of Phased Array Ultrasound

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have allowed increased access
to mining operations

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to improve their NDT programs
with this exciting technology.

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Phased array has been great for us
because

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we are able to get into a lot more
areas than we were able to before.

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With conventional UT you are
pretty limited on your access

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You have to have such
a greater soundpath

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so with phased array we get
all those other angles

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in a shorter span.

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We do a lot of work to AWSD 1.1

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and table six two and six three.

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And those require us to use forty-five
sixty and seventy

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depending on the thickness
of the part,

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so we can get that all in one shot

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so it really saves the time it takes
us to UT a weld.

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Phased array offers wider coverage,

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better POD,

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recordable results,

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and increased ability to monitor
defects for growth

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while retaining portability
for difficult access areas.

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Because of the flexibility of
phased array

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a single probe can be applied
to many different inspection

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scenarios and applications
without changing equipment.

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Mining equipment ultrasound
applications can be difficult;

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large and long parts,

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complex geometries,

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reduced access without
complete disassembly

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are only a few of the
inherent difficulties

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faced by NDT inspectors
in the mining industry.

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Many tests are designed
as a “best fit”

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or require multiple wedge changes
or special transducers

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to be designed to
accommodate the test.

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We do have some parts that

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we had to draw out in a CAD model

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and figure out which
angle is the best.

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One part for example,
we found out that a 55 degree angle

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was the right angle you need
for that part to find that crack,

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and with phased array we
can pretty much eliminate

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buying a 55 degree wedge

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and just use our regular transducer
and wedge on that.

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Conventional ultrasonics
can only be applied

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at one angle at a time,

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limiting the coverage
and detection capability,

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especially when the components
are in place in the equipment.

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If a crack is found

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typically only the inspectors
measurement

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or a report is saved.

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Swing shafts are a critical
component in draglines.

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As it is preferable not to
shut down the dragline

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manual ultrasonic inspections
are usually done in place.

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Identification of a crack is left
to the operators ability

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to identify the defect
in the A-scan display

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while moving the probe.

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With the shaft in place,
the ultrasonic inspection is limited.

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Phased array offers a sweep of beams

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allowing more coverage of
the shaft from the accessible area.

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Imaging makes the
inspection more reliable

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especially on shafts with known cracks

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that are being monitored.

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Adding a scanner or
encoder to the inspection

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makes these inspections
more reliable by

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being able to inspect from
the same exact position each time.

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Draglines and shovels contain
many bores or lugs

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connecting components together
with pins and shafts.

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These are high stress areas

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that tend to crack
on the inner diameter.

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They can be difficult to
inspect when in place

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due to probe access restrictions
from other components

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and reflections from geometry
of the part or other parts.

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Phased Array allows
more inspectable area

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from the accessible area

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and the imaging helps the inspector

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understand the geometry
signals more clearly.

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Many other components
can also be inspected.

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Almost all mining equipment
has many sizes of gears.

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Gear tooth integrity is crucial
to continued operation.

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Knowing the extent of cracking

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and if a gear tooth will break
off is critical.

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The inherent benefits of phased array

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proven by twenty plus years
of use in other industries

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are a big advantage for
typical mining industry applications.

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The use of multiple angles and imaging

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increases coverage,

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reduces scanning times,

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and provides better detection

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and characterization capabilities

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especially in crack growth
monitoring situations.

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Phased array can reinforce and enhance

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mine predictive maintenance programs

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and in turn increase profitability.

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Current trends for lower cost
and easier to operate units

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make these instruments more accessible
to mine NDT personnel

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enabling the conversion of
conventional ultrasonic tests

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to phased array ultrasonic tests.

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For more information on
Olympus mining solutions

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contact your local representative

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or visit us online at
www.olympus-ims.com.