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HKN ASARCO Stack Report

HKN ASARCO Stack Report

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The stacks are strong, straight and solid.
The stacks are strong, straight and solid.

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Published by: jimhtolbert434 on Nov 26, 2012
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

Save The Stacks El Paso, TX Asarco 828’ Concrete Stack
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

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

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

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

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION I—Executive 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 chimney’s 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.

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION II—Introduction 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.

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION III—Stack Descriptions Reinforced Concrete Column with Concrete Liner Constructed in 1966 Wind load design 100MPH

Construction: 828’ Concrete Reinforced Column 62’ 6”od. Wall thickness at BOS 36” TOS 9” Liner: Test Ports: Platforms: LPS: AWL: 828’ Concrete Reinforced Liner 20’0”. 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: 3’x7’ Door Accessible @ Base of Stack Breeching: 2

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION IV—Inspection 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.

All recommendations can be found in Section IX-Recommendations of this inspection report.

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection

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

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

740’ Elevation

720’ Elevation

700’ Elevation

680’ Elevation

660’ Elevation 9

Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

640’ Elevation

620’ Elevation

600’ Elevation

580’ Elevation

560’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

540’ Elevation

520’ Elevation

500’ Elevation

480’ Elevation

460’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

440’ Elevation

420’ Elevation

400’ Elevation

380’ Elevation

360’ Elevation 12

Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

340’ Elevation

320’ Elevation

300’ Elevation

280’ Elevation

260’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

240’ Elevation

220’ Elevation

200’ Elevation

180’ Elevation

160’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

140’ Elevation

120’ Elevation

100’ Elevation

80’ Elevation

60’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection North East South West

40’ Elevation

20’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack 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’ —

770’ — Exposed Structural Rebar

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

750’ —

730’ —

710’ — Needs Coating

690’ — Needs Coating
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

670’ — Surface Cracks

660’ — Minor spalling and surface cracks

630’ —

610’ —
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

590’ —

570’ —

550’ —

530’ — Structural Bolts/Hardware need coating

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

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

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

Exterior Conclusions Schmidt Hammer Testing Results (continued)
Elevation (ft) 400 380 360 340 320 300 280 260 240 220 200 180 160 140 120 100 80 60 40 20 North (psi) 4600 4600 4800 4800 4600 4600 4400 5000 4800 4900 4600 4800 4600 4800 4400 5000 4600 4600 4000 4400 East (psi) 4800 4600 4600 5000 4800 4400 4400 4600 4800 4600 4800 4600 4400 4800 4800 4400 4800 4800 4400 5000 South (psi) 4200 4400 4200 4000 4400 4200 4000 4400 4200 4000 4400 4600 4200 3800 4400 4200 4400 4200 3800 4000 West (psi) 4500 4200 4000 4200 4200 4400 4500 4500 4400 4200 4600 4400 4000 3800 4500 4000 4800 4600 4600 4200

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

510’ —

500’ — Damaged and Loose Structural Bolts

460’ — LPS Grounding on the Ladder System

420’ —

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

400’ — Needs Coating

380’ —

360’ —

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

340’ —

320’ —

300’ — Missing Structural Bolts

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

280’ —

260’ —

240’ —

220’ — Loose Structural Bolts
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

200’ — Loose Structural Bolts

160’ —

160’ — Oxidation Present

140’ —
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

120’ — Cracking of Concrete at Mounting Anchors

100’ — Heavy Oxidation Present

80’ — Cracking of Concrete at Mounting Anchors

60’ — Safety Cage is Damaged
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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Ladder System

40’ Ladder System Terminates Missing lower 40’ of ladder system and cage

Aviation Warning Light (AWL) System

AWL Located at the 500’ el. Personnel Platform

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Aviation Warning Light (AWL) System

Mid point Marker Lights located at the 650’ el. Personnel Platform

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Aviation Warning Light (AWL) System

AWL Located at the 800’ el. Personnel Platform Electrical Conduit freely rusting

Personnel Platforms & Structural Supports

800’ — Personnel Platform

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Personnel Platforms & Structural Supports

650’ — Personnel Platform Needs Coating

500’ — Personnel Platform

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Personnel Platforms & Structural Supports

800’ — Structural Supports of Personnel Platform

650’ — Structural Supports of Personnel Platform

500’ — Structural Supports of Personnel Platform

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Personnel Platforms & Structural Supports

420’ — Rest Platform /Oxidation Present

200’ — Rest Platform

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Lightning Protection (LPS) System

Cap is in very poor condition. Many loose and missing pieces. Needs to be removed ASAP for safety reasons.

LPS surrounding the Cap of the Stack with Lightning Rods

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Lightning Protection (LPS) System

LPS Grounding Connections

CAP

Cap is Covered in Oxidation and Heavy Corrosion. Sections have been removed.

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Cap

The Cap is completely covered in Oxidation and Corrosion. Cap is a complete Loss.

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION V—Stack Exterior Inspection Test Ports

Test Ports Accessible via Personnel Platforms

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION VI—Stack 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

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION VI—Stack Annulus Inspection Annulus

650’ Elevation

600’ Elevation

550’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION VI—Stack Annulus Inspection Annulus

500’ Elevation

450’ Elevation

400’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION VI—Stack Annulus Inspection Annulus

350’ Elevation

300’ Elevation

250’ Elevation

42

Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION VI—Stack Annulus Inspection Annulus

200’ Elevation

150’ Elevation

100’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

SECTION VI—Stack Annulus Inspection Annulus

50’ Elevation

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

Section VII—Conclusions 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,

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Save The Stacks El Paso, TX 828’ Concrete Stack October 2012

Section VIII—Recommendations 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)

(2B) (2B) (3A) (3A)

These recommendations should be addressed in a timely manner to avoid further loss of structural integrity and mitigate Immediate Safety Hazards.

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