Engineering, Testing, Consulting and Inspection Services

Engineering, Testing, Consulting and Inspection Services

We Take A Closer Look!

What is it? Why should you care?

Structural Integrity


Equipment and structural failures result in – 1) Worker Injury 2) Worker Fatalities 3) Lost Production Between 2000 & 2009 (according to Virginia DMME) accidents resulted in – 1) Forty-six (46) serious injuries 2) Eight (8) fatalities

Structural Integrity – Why Should you Care?


1) Protect miners from injury and death 2) Reduce downtime and lost production

Why do you want a structural integrity

program?



Truck driver fatally injured at the surface of underground salt mine. Victim was loading his truck under a 150 ton salt bin when it collapsed, falling on to the cab of the truck

Cargill –Cayuga Mine (2010)


- Routinely examine metal structures for indications of weakened structural soundness - Keep corrosive material spillage/build-up removed - Report all areas where indications of structural weakness are found

Resulting best practices or conclusions


Lab worker fatally injured after being buried in debris while exiting a building. The bottom cone section began with a one foot long split that quickly propagated

Dravo Lime Company – Black River Plant (1998)


Truck driver fatally injured while attempting to load rock from a rock chute. The lower cone portion of the rock bin failed, releasing approximately 150 tons of rock on the truck cab.

Jim Walter Resources – No. 5 Mine (1995)


Worker fatally injured when the roof of a 250 foot cement silo collapsed.

Titan Americas – Pennsuco Plant (2012)


Worker fatally injured due to sand fines silo collapse.

Luck Stone Corporation – Leesburg Plant (2015)


Luck Stone Corporation – Leesburg Plant (2015)


•Routinely examine metal structures for indications of weakened structural soundness and report indications •Periodic detailed inspections (both inside and outside) should be performed which examine hopper and wall thicknesses, critical connections and the material flow conditions. •Report any changes in the discharge flow pattern which could cause non-uniform pressures on the silo structure. •Schedule inspections of the silo’s interior surface only when all material has been removed to determine if it has become polished and worn from use.

Management of assets to ensure they are properly designed and installed, and are operating properly and all elements are fit for continued service and operation. A structural integrity program should take into account the inspection, testing, evaluation, and repair of the assets using procedures that are recognized and generally accepted good engineering practices (RAGAGEP), and should also consider the suitability of newly-fabricated equipment for usage. Written procedures should be established and implemented, and employees tasked with maintaining the ongoing integrity of the assets.


1. Inventory of assets

2. Review and categorize asset risks and priorities

3. Develop a written inspection plan

4. Inspection

5. Evaluation

6. Recommendations and Repairs


1. Assets typically would be considered as follows: a) Fixed equipment 1) Bins/Hoppers/Tanks b) Rotating/moving equipment 1) Crushers 2) Screens 3) Conveyors 2. In the mining industry, the following should also be included

a) Supporting structures (steel and concrete) b) Retaining walls c) Loadout Docks d) Surge tunnels


1. Risk can be evaluated by considering several areas:

a) Potential for failure b) Result of failure

I. Miner/personnel safety II. Financial loss due to downtime III. Environmental

2. Ranking assets by risk will assist to:

a) Provide the appropriate financial resources to the right area or asset


1. Inspection types

2. Inspection frequencies

3. List damage mechanisms

4. Identify critical areas

5. Inspection methods & approaches


1. Identifying damage mechanisms will: a) Reduce inspection costs b) Provide focus to key areas to reduce risk c) Thickness (10 years) d) Periodic walkthrough/checklists (monthly)

2. Types of damage mechanisms: a) Erosion or abrasion b) Corrosion c) Product/material considerations

a) Product acidity (when mixed with water) b) Chlorides or salts

d) Cyclic an/or nonuniform loading e) Vibration f) Vehicular traffic g) Foundation undercutting and settlement (due to washdowns)


1. Cone to shell attachments

2. Support attachments

3. Longitudinal seams/T junctions

4. Foundations

5. Any major load carrying structural member (i.e. columns)

6. High impact areas/heavy abrasion areas


1. Methods: a) Visual b) Non Destructive Examination (NDE) methods i) PT/MT for surface indications ii) Thickness (UTT)

2. Approaches a) External – Ground/Scaffolding or JLG/Rope access b) Internal

i) Physical entry ii) Rope access iii) Remote visual inspection (RVI) iv) Inspection ports (existing or added)


1. Cracking 2. General erosion and corrosion 3. Bolts and fasteners – missing/corroded 4. Distorted structural members

a) Vehicle damage 5. Small through holes 6. Coating condition 7. Excessive vibration or movement during operation 8. Undercut foundations 9. Concrete

a) Spalled b) Cracked c) Exposed rebar

10. Evidence of nonuniform material flow 11. Steel abrasion from conveyor belt


1. Appropriate details and specifications

a) Specifications should include: i) Material requirements ii) Welding details, qualifications, and acceptance criteria

2. Performed by qualified contractors or internally

3. Follow-up inspection or verification of the repair

4. If it failed once – it will fail again unless it is redesigned!


1. Provide training for existing miners or employees

a) Don’t assume they are looking for issues b) Don’t assume there are common defects or issues

2. Consider personnel outside of daily operations or from other facilities

3. Internal resources vs third party


This concludes our presentation. We hope that todays presentation assisted in educating you on Structural Integrity

and that the material presented will provide a background for a safer facility and more reliable operation.

Questions?


The mission of Applied Technical Services, Inc. is to be the premier provider of high quality testing, engineering, and inspection services. ATS will achieve this goal by understanding and anticipating customer needs and providing a healthy and safe work environment for all employees. ATS provides timely, cost effective services through the application of technologically advanced equipment and knowledgeable people. ATS is also committed to maintaining a financially strong organization that continues to grow in a planned and controlled manner, and encourages individual achievement.


Date post:	14-Jan-2022
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