Professional Documents
Culture Documents
October 19, 2012 Geoffrey Wright Save The Stacks 2112 Murchison Drive El Paso, TX 79930 Asarco 828 Concrete Stack
Mr. Wright, Thank you for your cooperation during the performance of this inspection project. Included you will find the Inspection Report, containing labeled photographs and recommendations for the maintenance of the Stack. It was a pleasure to work with you on this project. If you need any further assistance, please do not hesitate to call. Sincerely, John Susong
TABLE OF CONTENTS SECTION I SECTION II SECTION III SECTION IV SECTION V SECTION VI SECTION VII SECTION VIII EXECUTIVE SUMMARY INTRODUCTION STACK DESCRIPTIONS INSPECTION PROCEDURES STACK EXTERIOR INSPECTION STACK ANNULUS INSPECTION CONCLUSIONS RECOMMENDATIONS
SECTION IExecutive Summary In accordance with the Save The Stacks purchase order, Industrial Access, Inc. performed a condition assessment of the reinforced concrete column (windscreen) and reinforced concrete liner. Activities included reviewing pertinent documents, photographing anomalies, examination of the exterior concrete chimney along with the interior annulus space and concrete liner. Furthermore, the examination of the chimneys structural and mechanical equipment components, accessories and appurtenances were also completed. Evaluation of the significance of any detected degradation, deterioration, malfunction or damage to the stacks, and their associated equipment systems, appurtenances or accessories and mechanical integrity were all completed within the inspection scope. At this time we believe the chimney stack to be both structurally and mechanically sound. That is to say, it is able to perform its intended function of exhausting combustion byproducts mechanically and maintain its current configuration structurally for the foreseeable future barring acts of God type events outside of its original design parameters. There are, however, repairs that need to be made in order to maintain the above status. With the above statement in mind, the recommendations outlined in Section IXRecommendations of this report should be addressed to acquire and insure the maximum potential service life of the chimney stack as a structure.
SECTION IIIntroduction Industrial Access, Inc. was retained by Save The Stacks, LLC to conduct a mechanical condition assessment of the Asarco 828 Smelter Stack at El Paso, TX. A comprehensive exterior and interior inspection was performed at that time. Based on the inspection findings, recommendations for repairs are mentioned and assigned a corrective action factor. The Action Items (AI) are classified into six (6) factors. 1A1B2A2BImmediate concern or significant structural deficiency with imminent potential for loss of life, personal injury or structural failure of significance (potential forced outage). Immediate safety concern or significant non-structural deficiency with future potential for loss of life or personal injury. An examination scheduled as per the procedure guideline or sooner based recommendations made by plant observations or examinations. Moderate structural or non-structural deficiency which does not pose imminent potential for loss of life or structural collapse, but whose condition should either be corrected in the near future or be closely monitored in the future for evidence of further deterioration. Minor structural or non-structural deficiency which does not pose any threat to loss of life or structural integrity. Functional defiance which may affect the structure performance. Repairs are intended for better operation, maintenance. This priority will also be used for identifying scheduled inspections. Non-structural deficiency which does not pose any threat to loss of life or structural integrity. Repairs are intended for better appearance.
3A-
3B-
Members of the Industrial Access Inspection Site Team were: John Susong Bob Rielly Tommy Henderson John Powell Vince Humble Project Manger Rope Tech Rope Tech Rope Tech Robe Tech
This report presents our observations and together with our findings, conclusions, photographs, rehabilitation recommendations accompanied with recommended material specifications and pertinent publications.
SECTION IIIStack Descriptions Reinforced Concrete Column with Concrete Liner Constructed in 1966 Wind load design 100MPH
Construction: 828 Concrete Reinforced Column 62 6od. Wall thickness at BOS 36 TOS 9 Liner: Test Ports: Platforms: LPS: AWL: 828 Concrete Reinforced Liner 200. Wall thickness BOS 36 TOS 10 Multiple Ports accessible @ 360 Personnel Platforms (3) (3) Full circumference platforms @ 800, 650, & 500 elevations. Two Down-Lead System Grounding Stack. Air Terminals Mounted @ top of Concrete Stack Triple Tier, Low Intensity Full Time Intermittent System @ 810 590 AGL and Midpoint Platform
Ladder Irons: Steel Rungs with Safety Cage extending to the top segment of the Concrete Stack Access Doors: 3x7 Door Accessible @ Base of Stack Breeching: 2
SECTION IVInspection Procedures Upon arrival of our crew and equipment on the job site, personnel, ladders, scaffolding and safety devices, all in strict accordance with OSHA and SPRAT safety regulations, were installed to carry out the work. The owner furnished 120 volts of power adjacent to the chimney termination for Industrial Access use. After the inspection was completed, our crew removed all debris from the area and disposed of the remains at an authorized dumpsite, leaving the site in an As Found or better condition. Exterior Inspection Industrial Access utilized rope access techniques to give access throughout the exterior of the concrete column (windscreen). Our crew performed an exterior visual inspection of the Stack. This inspection examined the surface for cracks, corrosion and other anomalies. During the exterior inspection the test ports, walkways, access plates, etc. were also examined. Photographs and documentation were taken at different locations depicting the conditions found. Annulus Inspection Industrial Access utilized rope access techniques to give access throughout the Annulus of the concrete column and liner. Our crew performed an extensive Annulus visual inspection of the Stack. This inspection examined the surfaces for cracks, corrosion and other anomalies. During the Annulus inspection the test ports, walkways, access plates, etc. were also examined. Photographs and documentation were taken at different locations depicting the conditions found.
Exterior
Pictures are of the North, East, South, and West bearings of the exterior stack with elevations listed below. The pictures are meant to be a visual sample of the stack at the given elevation and directional. The exterior inspection was done at 20ft intervals beginning at elevation 810ft AGL and ending at elevation 0ft. External Cracking and Spalling of the concrete shell was found in the upper 30 at TOS. Corrosion of rebar was not found to be evident at this time.
North East South West
810 Elevation
800 Elevation
780 Elevation
760 Elevation
740 Elevation
720 Elevation
700 Elevation
680 Elevation
660 Elevation 9
640 Elevation
620 Elevation
600 Elevation
580 Elevation
560 Elevation
10
540 Elevation
520 Elevation
500 Elevation
480 Elevation
460 Elevation
11
440 Elevation
420 Elevation
400 Elevation
380 Elevation
360 Elevation 12
340 Elevation
320 Elevation
300 Elevation
280 Elevation
260 Elevation
13
240 Elevation
220 Elevation
200 Elevation
180 Elevation
160 Elevation
14
140 Elevation
120 Elevation
100 Elevation
80 Elevation
60 Elevation
15
40 Elevation
20 Elevation
16
SECTION VStack Exterior Inspection Ladder System The Ladder System is a Steel Rung Ladder with a Safety Climb Cage. The Ladder begins at the 40 el mark and is continuous to the Stacks Cap. The Ladder System was inspected by our team for any damage, cracking, and anomalies associated with. Photographs below are presented with elevation markers of the Ladder System.
Ladder System extending to the Cap Oxidation and Corrosion Heavily Present
790
17
750
730
630
610
19
590
570
550
20
Exterior Conclusions Schmidt Hammer Testing Results of the Exterior Concrete Stack are documented below.
Elevation (ft) 810 800 780 760 740 720 700 680 660 640 620 600 580 560 540 520 500 480 460 440 420
North (psi) 4500 4500 4400 4400 4400 4400 4600 4600 4900 4600 4600 5000 4600 4200 4800 4800 4100 4800 4600 4800 4200
East (psi) 4300 4500 4600 4200 4600 4600 4200 4400 4600 4900 4000 4800 5000 4400 5000 4800 4200 4800 4400 4600 4600
South (psi) 4200 4600 4400 4400 4000 4400 4000 4000 3800 4000 4000 4400 4000 4000 3800 4200 4400 3800 4200 4000 4600
West (psi) 4100 4500 4600 4600 4200 4000 4200 4200 4000 4200 3800 4200 3600 4000 4200 4000 4400 4000 4000 3800 4400
21
22
510
420
23
380
360
24
340
320
25
280
260
240
160
140
27
29
Mid point Marker Lights located at the 650 el. Personnel Platform
30
AWL Located at the 800 el. Personnel Platform Electrical Conduit freely rusting
31
32
33
34
Cap is in very poor condition. Many loose and missing pieces. Needs to be removed ASAP for safety reasons.
35
CAP
Cap is Covered in Oxidation and Heavy Corrosion. Sections have been removed.
36
The Cap is completely covered in Oxidation and Corrosion. Cap is a complete Loss.
37
38
SECTION VIStack Annulus Inspection Annulus The following documentation was collected in the Annulus of the Stack. Industrial Access utilized Rope Access Techniques to Inspect the current condition of the Inner Wind Screen and outer Liner. The entire height of the Stack was documented from the Cap to the Base.
800 Elevation
750 Elevation
700 Elevation
39
650 Elevation
600 Elevation
550 Elevation
40
500 Elevation
450 Elevation
400 Elevation
41
350 Elevation
300 Elevation
250 Elevation
42
200 Elevation
150 Elevation
100 Elevation
43
50 Elevation
44
Section VIIConclusions Annulus Conclusions Upon completion of the Annulus Inspection, Industrial Access has found the Annulus Space of the Concrete Stack to be in Very Good. Taking into consideration the age of the Stack, the amount of Spalling in the Annulus Space is minimal. There was no indication that there was any leaking flue gas into the Annulus Space from the Chimney Liner. At this time there are no immediate concerns associated with the Annulus Space. No thermal cracks were found in the liner,
45
Section VIIIRecommendations Based on the Inspections findings, the following recommendations for the maintenance and repair of the 828 Concrete Stack are submitted. Please see Section II for Action Item (IA) Classifications. Exterior: (1A) (1B) (2A) Remove existing Cap and Structural Steel Install New Custom Cap Replace Sections of LPS that are Heavily corroded or broken. Tool Clean Ladder System Replace & Repair Damaged Sections of the Ladder System and Anchor Points Apply Tnemec Primer and 2 Coats of Tnemec Coating to Ladder System Strip and Tool Clean Exterior Concrete WindScreen Hydroblast Concrete Windscreen Inject Concrete Epoxy to Cracking and Spalling sections as needed Apply Tnemec Primer and 2 Coats of Tnemec Coating to Concrete Windscreen Tool Clean Personnel Platforms and Safety Rails Apply Tnemec Primer and 2 Coats of Tnemec Coating to Steel Structures Repair/Replace AWS Electrical Conduit and Wiring in Damaged areas of Corrosion Lower interior liner to level of outside wind screen Prepare and Carbon fiber Wrap top 40 of stack
(2B)
These recommendations should be addressed in a timely manner to avoid further loss of structural integrity and mitigate Immediate Safety Hazards.
46