Cases

Structural Integrity

Structural finite element analysis, stress analysis using extensometers, and integrity assessment employing inspections and NDTs for two STS cranes ZPMC 40T and a dockside crane TAKRAF 32-40T. For the dockside crane, a Structural Recovery Procedure was also prepared.

Structural Integrity

Structural integrity assessment (inspection and NDTs) mapping 610 structural anomalies points, classification of criticality levels and prioritization of interventions, preparation of study and procedure for structural recovery with critical steps details, and standardized procedures for recurring anomalies repair.

Structural Integrity

Structural analysis of the three STS cranes evaluated; structural integrity assessment (Risk-Based Inspections and NDTs), and experimental stress analysis using extensometers.

Structural Integrity

Finite element analysis, structural integrity assessment, and preparation of structural drawing as-built for overhead cranes of Tubarão complex Pelletizing and Port, in Vitória – Espírito Santo.

The main points of this work were: 

  • Explicit the conditions considered in the overhead crane project, as the applied load and load spectrum
  • Present stress and global deformation of the structure
  • Present a life fatigue study for the overhead crane
  • Assess structural stability of the structure

Asset Management, Integrity and Risks

Structural analysis and structural integrity assessment (visual inspection, drone inspection, and NDTs) for two STS cranes, fourteen rubber-tired gantry cranes, and two mobile harbor cranes.

Development of an integrity management system to control the 828 corrective actions. The system includes prioritized damages by severity and criticality of damage location, statistics, damage maps, traceability system, and representative photographs of each damage.

Project and Development

Study of failure modes of the main rod flanges. Development of a solution to eliminating this failure mode with a new project and parts for field adaptation of submersible articulated buoys.

Project and Development

Development of a Geotechnical Sounding Platform, equipment for sounding the sea floor at depths of up to 25m.

Project and Development

Improvement and adequacy projects of mechanical and structural systems in the SunCoke machinery area for 2 years.

Project and Development

Re-design of SunCoke Energy’s industrial water and fire-fighting system, discontinuing operation of underground piping network.

Asset Life Extension

Study of failure modes for rotor bearings and development of a solution in order to restore the reliability of the equipment. After implementing the recommendations, the equipment returned to operate under ideal conditions with an increase in MTBF.

Asset Life Extension

Study of failure modes of the refractory ceiling support assembly in the “nose” region by thermal and structural analysis, as well as the combination of their effects. Based on the study, R1 developed a customized solution allowing better assembly performance and increasing equipment reliability.

Asset Life Extension

Thermomechanical finite element analysis for the grid cars, evaluating plastic collapse, brittle fracture, and crack propagation in the structure, which made it possible to extend the life of the assets by up to five years.

Asset Life Extension

Structural analysis to verify the risk of collapse and crack propagation analysis in the structure of a screw mixer for petroleum coke blend. Despite the absence of the risk of imminent collapse, the analyzes demonstrate the risk of not stabilizing the crack propagation, providing the customer with a time forecast for maintenance.

Asset Life Extension

Finite element analysis of an ash storage silo in its design condition and in the deformed condition obtained with 3D scanning. The analyzes allowed the elaboration of a Structural Recovery Procedure and the proposition of reinforcements for the maintenance of the silo, incurring in the extension of the asset’s life.

Consulting and Adequacy Study

Inspection of 29 fall protection lifelines, verifying their physical condition in order to certify the equipment for safe use.

Consulting and Adequacy Study

Study of the adequacy of an overhead crane to Brazilian Regulatory Standards, describing guidelines for electrical improvements, adequacy to current safety standards, and good operational pratices

Consulting and Adequacy Study

Diagnostic study of the system and lighting around the SunCoke Batteries and Retentions, with inspection, measurements of light levels and study of alternatives in the market to reduce energy consumption.

In addition, budgeting was carried out to adapt the system to regulatory standards and modernization, as well as the implementation schedule.