The Importance of Non-Destructive Testing in the Mining Industry
There’s a lot of digging in mining, that’s a given. But digging blind can open up a world of problems, from structural destruction to workplace accidents. Non-destructive testing (NDT) provides mining companies with valuable information about their equipment, materials, and dig sites, leading to safer and more efficient operations.
In this post, A.I. Inspection will talk you through non-destructive testing in mining and discuss how this very effective method can benefit your next project.
What is NDT?
Non-destructive testing examines materials, components, equipment, and other properties to understand their make-up. It looks for flaws, faults, or anomalies so project managers know exactly what it is they’re working with. NDT differs from traditional methods as it employs various non-invasive techniques to analyse specimens without damaging them, making it a safer, more cost-effective testing solution.
How Does NDT Benefit Mining Operations?
Mining is a heavy-duty gig, and one that requires incredible foresight. While you can’t always guarantee the bounty, NDT allows you to manage the risks, helping keep your project on track. Benefits of non-destructive testing in mining include:
Increased Safety
If you work in the mining industry, you know how crucial it is to get on top of problems early. If you don’t, well, then there goes your whole project. Whether it’s a machine breakdown or a serious injury, halting operations is never ideal.
NDT is vital for mining safety. These inspections prevent downtime and identify potential risks early on, ensuring safer working conditions for you and your crew.
Cost-Effective Maintenance
If you notice a nail in your car’s tyre, do you remove it and plug the puncture or let the air drain and wait for the rim to demolish the rubber? NDT allows you to stop small defects in their tracks, preventing them before they turn into large, costly repairs.
Additionally, prompt repairs mean more time on the job, ensuring you continue covering operational and wage costs, rather than incurring out-of-pocket expenses.
Enhances Equipment Reliability
Regular non-destructive testing ensures that all machinery and infrastructure are functioning correctly. By maintaining high reliability levels, mining operations can proceed smoothly without unexpected interruptions caused by equipment failure. Plus, proper maintenance based on accurate assessments ensures that machinery remains in good condition for longer periods, ultimately increasing its lifespan.
Mitigates Environmental Risks
NDT is an environmentally friendly alternative to traditional mining site testing methods. Because it doesn’t damage target materials, non-destructive testing reduces waste and resource consumption. It also prevents unnecessary disposal of usable parts and helps mitigate environmental accidents such as spills and leaks.
Quick Damage Assessment Where it Counts
In case of emergencies such as storms or fires, non-destructive mining site safety inspections offer a swift way to assess damage. They provide real-time data, allowing for quick decision-making about necessary repairs or safety measures.
Understanding Tricky or Hard-to-Reach Places
NDT is particularly beneficial for inspecting unsafe or hard-to-reach areas, providing mine operators and personnel with valuable insights about their projects.
When to Use Non-Destructive Testing in Mining: Types and Applications
There are various types of NDT used in the mining industry (standard and advanced), many of which we provide here at A.I. Inspection. NDT applications depend on the materials, components, or properties you need to evaluate. Here’s a bit of a breakdown:
Standard
Surface Inspections
Used to detect flaws in a material’s surface and includes methods such as:
- Magnetic Particle Inspection: Separates magnetic material from non-magnetic material from a surface, usually with non-ferrous metals such as carbon steel..
- Dye Penetrant: Applied to reveal hidden cracks or defects, usually with non-ferrous materials such as Duplex, aluminium and high-grade stainless steel.
- Coating Inspection: Checks protective coatings on equipment and infrastructure for voids or pinholes.
Volumetric Inspection
Techniques to assess internal structures and detect subsurface flaws.
- Ultrasonic Inspection NDT: High-frequency sound waves to identify defects such as cracks or lack of fusion in materials or welds.
- Radiography & Profile Radiography (Digital): Uses x-rays or gamma rays to visualise and inspect hidden imperfections or voids inside materials and structures. Suitable for pipes, welds, and mining equipment inspections.
Electromagnetic Inspection
Uses electromagnetic fields to identify irregularities.
- Eddy Current NDT: Induces electrical currents in metals and other conductive materials to detect disruptions caused by flaws, cracks, and corrosion. Often used on pipes, tubes, drills, tanks, and rail tracks.
Mechanical Testing
Evaluates physical properties without causing permanent damage.
- Bend Test & Macro: Bends materials and cross-sections to test their ductility and flexibility. Ideal for testing metals, like beams, pipes, and supports.
- Portable Hardness Testing: Uses portable devices to directly measure hardness and assess resistance and strength.
Specialised Equipment Inspection
NDT that inspects and protects mining equipment.
- Vessel Inspection: Ensures pressure vessels meet safety standards by checking for wear, corrosion, and other potential issues that could compromise integrity.
- Lifting Equipment Inspection: Evaluates cranes, hoists, and other lifting devices for signs of stress or fatigue that might lead to failure during operation.
Visual and Optical
Advanced visual techniques.
- Borescope Inspection: Inspects and examines confined spaces without disassembly. Suitable for pipes, engines, and other finicky environments.
Advanced
Eddy Current Methods
Uses electrical currents to check materials for damage or defects.
- Pulse Eddy Current Technology (PECT): Detects corrosion and defects in metal through electromagnetic fields. It is particularly useful for inspecting covered or coated materials, such as pipes, bridges, and machinery.
- Eddy Current Array Technology (ECA): Uses multiple sensors to find surface cracks and flaws in conductive materials. Effective in aircraft and railway maintenance and manufacturing.
Ultrasonic Methods
Employs high-frequency sound waves to identify cracks and flaws.
- Phased Array Ultrasonic Corrosion Mapping: Uses sound waves to create detailed images of corrosion in materials. Ideal for pipes, metal structures, and mining equipment.
- Phased Array Ultrasonic Weld Inspection: Examines welds for defects by sending ultrasonic waves at different angles. Effective testing method for construction sites, shipbuilding, and the automotive industry.
- Time of Flight Defraction NDT Weld Testing: Measures sound wave travel time to detect weld flaws, and is particularly useful in power plants, railway tracks, and the aerospace industry.
Remote Inspection Methods
Cameras, drones, and robots that safely inspect materials and structures.
- Aerial Drone Inspection: Uses flying drones to capture images and data from distant or hard-to-reach places. Suitable for inspecting buildings, bridges, roofs, and large pieces of land.
- ROV Inspection: Uses remotely operated vehicles to inspect underwater structures and tanks. Particularly useful for detecting fire water tanks and underwater equipment.
Ask AI Inspection About Our NDT Solutions Today
At AI Inspection, we don’t just use NDT methods to conduct mining site safety inspections; we pioneer them. Dedicated to safety and creating a sustainable future, we truly believe non-destructive testing is the way of the future.
First Nations led by our founder, Duane Coulthard, A.I. Inspection is committed to providing the best industry practices to companies with Aboriginal advancement initiatives and remains steadfast in closing the gap for Aboriginal and Torres Strait Islander people. Get in touch with us on 0437 904 979 or at info@ai-inspection.com.au to discuss non-destructive testing options for your mining site.