“By using the UIT process during a weld repair we have eliminated our unscheduled outages during the course of the year and only perform an annual inspection and repair, if required.”
Randy Warnock, Client Field Maintenance Supervisor
UIT SOLVES DRAGLINE BOOM CRACKING PROBLEM FOR MINING BUSINESS
Mines across the country are experiencing repetitive cracking in critical areas in the masthead of their 1370 and 1570 Bucyrus draglines. To fix these masthead crack problems, the mine owner must either perform repetitive repairs, costing lost production, or a multi-million dollar redesign. Applied Ultrasonics provides an innovative third solution: a fast, simple repair that lasts years instead of months.
WELD REPAIR SITUATION
The clients' phosphate mine in Florida was spending considerable time and money to weld repair problem areas in the masthead on their two 1370’s. To address these masthead cracks, the client performed a 5 day repair, repeated every 6 months. At $10,000 an hour on downtime costs, this is a costly problem. The dragline manufacturer’s redesign fix requires laying the boom down and retrofitting the problem area with thicker plate. This procedure takes 30-45 days, costing the mine $7-10 Million in lost production and downtime costs. The mine maintenance supervisor decided to use Applied Ultrasonics' UIT services, representing a whole new mining technology for tackling dragline repair problems.
UIT RESULTS
In May 2011, a Applied Ultrasonic Technology (UIT) team arrived at the mine site to employ their innovative repair methodology and worked in conjunction with Bucyrus welders. There was one variation to the typical mining business' weld repair procedure - they used Ultrasonic Impact Technology for onsite stress relief in place of post weld heat treatment. This minor change shortened the repair time and substantially improved the results. With the Applied Ultrasonics's repair procedure, the masthead passed the Bucyrus inspection with no cracks at the six month mark. The dragline continues to operate crack free, and after 11 months UIT has added an estimated $1 Million to the customer’s bottom line.
UIT EFFECTS
- INCREASE LIFE OF REPAIRS FROM MONTHS TO YEARS
- RELIEVE WELDING STRESS
- REFURBISH OLD MATERIALS, INCLUDING PREVIOUS REPAIRS
- PREVENT FATIGUE AND FRACTURE
UIT BENEFITS
- REPLACE POST-WELD HEAT TREATMENT
- FINISH REPAIRS AND MODIFICATIONS FASTER
- DECREASE DOWNTIME FOR REPETITIVE WELD REPAIRS
- SAVE MONEY ON REPLACEMENT / REDESIGN COSTS
FATIGUE STRENGTH STUDY
Applied Ultrasonics' Ultrasonic Technology (UIT) is a boon for infrastructure management and has repeatedly extended time to fatigue failure for ageing infrastructure and assets, from bridges to mining business equipment to offshore rigs. Applied Ultrasonics' Ultrasonic Tehcnology (UIT) Division can provide service onsite to maximize cost effectiveness for the customer. To learn how Applied Ultrasonics can help your company, please contact us.
