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
Also very
dirty….
• Thick and complicated

• Culture of SAFETY
 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 • Propel-Main shafts-Intermediate shafts,

• Mast anchors, lugs, links and pins Stabilizer Arms, Lifting hooks

• Back leg anchors, lugs, links and pins • Fairlead Pins

• Main suspension pins, attachment plates • Hoist and Drag Drum Stub Shafts

• Intermediate suspension pins, attachment • Drum Split line bolts

plates • Drum to spider bolts

• Swing Shafts • Hoist and Drag Intermediate Shafts

• Boom point shaft • Center Pin

• “Sticks” • 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