1. Robert Mitchell.
Rio Tinto Western Australia.
Brockman 2.
MEM NDT of ANCILLARY VEHICLES.
4/02/2016
Created by Robert Mitchell. Eng Tech: Member B.InstNDT: LEP WTIA: AINDT.
The use of noninvasive techniques to determine the integrity of a material, component or
structure or quantitatively measure some characteristic of an object.
i.e. Inspect or measure without doing harm.
2. NDT Inspection of heavy fleet
machines in the mining industry.
• Written and researched by
• Robert Mitchell.
• Eng Tech: M.BInstNDT: L.E.P: WTIA: AINDT.
3. Non-destructive testing (NDT) is a wide group of analysis
techniques used in science and industry to evaluate the
properties of a material, component or system without causing
damage. The terms Non-destructive examination (NDE), Non-
destructive inspection (NDI), and Non-destructive evaluation
(NDE) are also commonly used to describe this technology.
Because NDT does not permanently alter the article being
inspected, it is a highly valuable technique that can save both
money and time in product evaluation, troubleshooting, and
research. Common NDT methods include ultrasonic, magnetic-
particle, liquid penetrant, radiographic, remote visual inspection
(RVI), eddy-current testing. NDT is a commonly used in forensic
engineering, mechanical engineering, electrical engineering, civil
engineering, systems engineering, aeronautical engineering,
medicine, and art.
NDT Inspection
4. EYES ON THE INSPECTION THE
QUALITY IS IN YOUR HANDS!!!!!!
11. LeTourneau L2350 Loader v3
Cracks
Defect 1: Underneath front frame left hand side rat hole cracks.
Defect 2: Cracks Below: 20mm length 200mm distance
apart, 100mm from the top plate. Right hand side: Rear
frame. Side plate baffle stiffener
12. LeTourneau L2350 Loader v3 Cracks
Defect No 3:- front frame the crack extends from the plate into
the front ball pivot socket around 300mm length
18. Komatsu 730E-07 Haul Truck showing
corrosion below in the “A” from below cab.
Corrosion
“A” frame
19. Corrosion.
What Causes Corrosion
Corrosion is caused by the reaction of a metal with the environment; a
typical example of corrosion is the red rust on iron.
Rust is made of different iron oxides like Fe2O3, Fe3O4 that form due to the
reaction of Oxygen dissolved in water with Iron:
2Fe + O2 + 2H2O -----> 2Fe(OH)2
Fe(OH)2 is unstable in oxygenated solution and reacts:
2Fe(OH)2 + H2O + 1/2O2 -----> 2Fe(OH)3
The final products is the red rust.
20. WELDING DEFECTS
According to the American Society of Mechanical
Engineers (ASME), welding defect causes are broken down
as follows: 45 percent poor process conditions, 32 percent
operator error, 12 percent wrong technique, 10 percent
incorrect consumables, and 5 percent bad weld grooves.
21. Types of cracks
1:-Top left:- Centre line Crack.
2:- Top right:- Side wall Crack.
3:- Bottom left:- Root Crack.
22. Example: Longitudinal cracks.
Longitudinal cracks run along the length of a weld bead.
There are three types: check cracks, root cracks, and full centreline
cracks.
Check cracks are visible from the surface and extend partially into
weld. They are usually caused by high shrinkage stresses, especially
on final passes, or by a hot cracking mechanism.
Root cracks start at the root and extent part way into the weld. They
are the most common type of longitudinal crack because of the small
size of the first weld bead. If this type of crack is not addressed then it
will usually propagate into subsequent weld passes, which is how full
cracks (a crack from the root to the surface) usually form.
Longitudinal or centreline cracking, of the weld bead is not often
encountered in mig welding. However, that which does occur can be
one of two types: hot cracks and cold cracks. Hot cracks are those that
occur while the weld bead is between the liquidus (melting) and solidus
(solidifying) temperatures.
23. This presentation was only meant to show the differing ways NDT
can be performed by which Non Destructive Testing can be used in.
I hope this has helped you….
The End.
This was a presentation researched by
Robert Mitchell Eng Tech: M.InstNDT: L.E.P: WTIA & AINDT.
An NDT Inspector is a highly trained individual who is responsible for
finding damage in any products, components, or systems before it
becomes a major problem. They find damage before it reaches its limits.
They use NDT techniques and methods to ensure the safety of any
component or structure.
Editor's Notes
This presentation was researched by Robert Mitchell for NDT Education to provide students and other audiences with a general introduction to nondestructive testing. The material by itself is “not intended to train individuals” nor to perform NDT functions, but rather to acquaint parties with some areas where NDT methods are used. All rights are reserved by Robert Mitchell but the material may be freely used for educational purposes. The materials may not be sold commercially, or used in commercial products or services.
Try to have eyes like the eagle an open mind and common sense……….
Powertrain / Integration: Combining the electronic engine control with the Caterpillar electronic transmission control allows these critical power train components to work more intelligently. . . Torque Divider: A single-stage torque converter with output torque divider sends 75 percent of engine torque through the converter, 25 percent through a direct drive shaft for greater driveline efficiency and higher torque multiplication. . . Transmission: Planetary Power Shift Transmission has three speeds forward and three speeds reverse and utilizes large- diameter, high-capacity, oil-cooled clutches. . . D11R Brakes: 1 Thick, large diameter plates and disks provide higher torque capacity and increased service life. 2 Brake housing has cast-in ribs for more durability and a new valve design. 3 Cooling oil valve controls 75 gallon per minute of oil (increase of 78 percent). 4 Clutch disks provide greater torque capacity on the clutch. 5 Tapered roller bearing design provides increased service life.
Power Train: Forward/Reverse Gears 8 Forward/6 Reverse. . . Transmission: Direct drive, power shift, countershaft. . . Brakes – Service Oil-actuated, oil-disc. . .Brakes – Service, Surface Area 49830.0 cm2. . . Hydraulic System: Circuit Type Electro-hydraulic load sensing, closed centre. . .Pump Type Variable piston. . . Maximum System Pressure 24150.0 kPa . . . Reservoir tank capacity 65.0 L. . .Standby Pressure 3100.0 kPa. . . Operating Specifications: Top Speed – Forward 53.9 km/h. . . Top Speed – Reverse 42.6 km/h. . .Turning Radius, Outside Front Tires 8.9 m. . .Steering Range – Left/Right 47.5°. . .Articulation Angle – Left/Right 20°.
Architecs drawing of the inspection area for the 16M cat Motor grader
This was a shut down inspection project which the machine had multiple cracking see the next 2 pages. Prior to the welder initiating the welding repair process the welder had to undergo a welder qualification test to the 4G position. . . Dimensions: Length with Bucket on Ground: 66.6 ft in (20300 mm). . .Width Over Tires: 22.2 ft in (6760 mm ). . .Wheelbase: 25.9 ft in (7880 mm). . .Height to Top of Cab. . .21.2 ft in (6450 mm). . .Ground Clearance. . .1.6 ft in (500 mm). . .Hinge Pin - Max Height: 32.5 ft in (9910 mm). . .Dump Clearance at Max Raise: 23 ft in (7020 mm). . .Reach at Max Lift and Dump: 10.4 ft in (3180 mm). . .Engine Make: Cummins Model: QSK 60: Gross Power: 2300 hp (1715.1 kw).. . .Power Measured @: 1900 rpm. . .Displacement: 2746 cu in (45 L). . .Aspiration: Turbocharged: Operational: Operating Weight: 577999.2 lb (262176 kg). . .Fuel Capacity. . .1050.1 gal (3975 L). . .Hydraulic System Fluid Capacity. . .382 gal (1446 L). . .Cooling System Fluid Capacity. . .130 gal (492 L).
This is the articulated pivot arm socket the cracks initiated from the socket into the parent material
Caterpillar D11R Track Dozer: Dimensions: Length w/ Blade 34.9 ft in 10637.5 mm. . .Width Over Tracks 11.8 ft in 3606 mm. . .Height to Top of Cab 13.4 ft in 4078 mm. . .Length of Track on Ground 12.7 ft in 3855 mm. . .Ground Clearance 2.2 ft in 674.5 mm. . .Length w/o Blade 19.8 ft in 6027 mm. . .Undercarriage: Track Gauge 9.5 ft in 2896 mm. . .Standard Shoe Size 28 in 710. . . Specification. . .Engine: Make Caterpillar. . .Model 3508BGross Power 935 hp 698 kw. . .Net Power 850 hp 634 kw. . .Power Measured @ 1800 rpm . . .Displacement 1958.9 cu in 32.1 L . .Aspiration -Turbocharged
Caterpillar D11R Track Dozer frame assembly showing most likely cracking in the weld inspection areas .
Top Speed – Loaded 60.4 km/h. . . Body Capacity - Struck 42.1 m3 . . . Body Capacity – SAE 2:1 60.1 m3 . . . Nominal Payload Capacity 90.4 tonnes. . . Weights – Approximate. . .Target Gross Machine Operating Weight 163360.0 kg. . . Operating Weight - Empty 64670.0 kg
The ball studs are examined ultrasonically once removed from the front axle of the truck as the ball stud in reality is a forged machined material.
This is a Komatsu 730E-07 Make and model. . .Komatsu SSA16V159 Fuel. . .Diesel Number of cylinders . . .16 Operating cycle . . .4 stroke *Rated brake power . . .1491 kW 2,000 HP @ 1900 rpm **Flywheel power . . .1388 kW 1,860 HP @ 1900 rpm Weight (wet). . .5294 kg 11,670 lb. . . AC/DC CURRENT Alternator . . .G.E. GTA-22 Control . . .Statex III Fuel saver *Motorized wheels . . .G.E. 788 **Ratio. . .26.825:1 Speed (maximum) . . .55.7 km/h 34.6 mph
There was also corroded areas on the left hand side of the “A” frame around the corner out of site.
Elimination of corrosion: Theoretically yes, it is possible but practically no. Usually the material and the method used to protect it from corrosion is a compromise between cost, reliability of the component and consequence in case of failure. You should first define the material and the environment conditions the material is going to be operation in and then you can define the corrosion control method that can reduce the likelihood of corrosion.
