___________________________________________________________________________________ Non-destructive testing incidents . These forms of communication start at the administrative level with policy , enter the realm of engineering controls with lock-out and Tag-out processes and finally come down to the most critical last-line of defense : line-of-sight and non-line-of-sight team communications . Someone needs to know where everyone is and what they are doing at all times on a large-scale shutdown .”
Back on the topic of NDT , Richard continues to explain the added value of the integration of NDT into the preventative maintenance plan of an asset ; “ One of the oldest and most effective tools in the preventative maintenance toolbox is NDT . For mining and processing assets ( grinding mills , crushers , tanks , pipes , mining shovels ) it offers a reliable , direct source of information for mechanical engineers , asset management professionals , risk analysts and specialized consultants who are part of overarching strategies to reduce operational risks .
“ Faster , less expensive and more reliable NDT inspection technologies are helping to optimize inspection planning and budgeting . The inspection frequency of any given asset should be directly linked to its operational risks ; the higher the risk , the higher the inspection frequency should be . At one mine site we work at , our team executed a successful preventative plan involving a high risk of catastrophic failure of a SAG mill ring gear . In this example , we were contracted to complete a 100 percent eddy current array scan of the gear teeth annually . This inspection cycle went on smoothly for several years without any significant findings until one year two cracks were detected . Immediately , ameliorative actions were taken , and the inspection frequency was increased to every six months to detect any new cracks . To monitor the cracks for propagation , we used phased array ultrasonic testing every one or two months . A spare gear was purchased with a 12-month lead-time . The crack growth trend showed that the teeth were holding up well enough that the mine would be able to run it long enough to plan and execute a gear change .”
Richard continues with a final statement and summary : “ Annual NDT inspection is generally recommended for gears , pinions and other rotating shafts such as conveyor pulleys . Other cyclically loaded structures such as mobile equipment and lifting devices should also be inspected annually . Thickness testing on rotating equipment should be done at least every 12 or 24 months , while thickness testing on tanks and vessels is recommended at 24-to-36-month intervals . These are of course general guidelines and not applicable to all cases ; each asset should be managed on a case-by-case basis . With good quality inspection data an experienced asset management consultant can provide great insight and value to a preventative maintenance plan . If good consultations are made and followed by the mine , then operating risk can be reduced .” ■
For a list of the sources used in this article , please contact the editor .
www . malenfantindustrial . com
Malenfant Technical Services ( MTS ) is an industrial services provider , specializing in 3rd Party Inspection and Non-Destructive Testing ( NDT ) services for mining and processing equipment and other heavy industrial assets . Despite operating primarily as a vendor for NDT , MTS offers a wide range of analytical solutions , providing more holistic services than a traditional NDT approach .
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Sena Industrial is one of the world ’ s leaders in Bluetooth ® communication devices for industrial and outdoor work environments . Its solutions are designed to address the demands of today ’ s industrial workers by offering more efficient , comfortable communications , better hearing protection , ease of deployment and use , and safer operation . All at a value unsurpassed in the industry .
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