hkn asarco stack report

7/30/2019 HKN ASARCO Stack Report

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Save The StacksEl Paso, TX

Asarco 828 Concrete Stack


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October 19, 2012

Geoffrey Wright

Save The Stacks2112 Murchison DriveEl Paso, TX 79930

Asarco 828 Concrete Stack

Mr. Wright,

Thank you for your cooperation during the performance of this inspection project. Included you will findthe Inspection Report, containing labeled photographs and recommendations for themaintenance of the Stack. It was a pleasure to work with you on this project. If you need anyfurther assistance, please do not hesitate to call.

Sincerely,

John Susong


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TABLE OF CONTENTS

SECTION I EXECUTIVE SUMMARY

SECTION II INTRODUCTION

SECTION III STACK DESCRIPTIONS

SECTION IV INSPECTION PROCEDURES

SECTION V STACK EXTERIOR INSPECTION

SECTION VI STACK ANNULUS INSPECTION

SECTION VII CONCLUSIONS

SECTION VIII RECOMMENDATIONS


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SECTION IExecutive Summary

In accordance with the Save The Stacks purchase order, Industrial Access, Inc. performed acondition assessment of thereinforced concrete column (windscreen) and reinforced concreteliner.

Activities included reviewing pertinent documents, photographing anomalies, examination ofthe exterior concrete chimney along with the interior annulus space and concrete liner.Furthermore, the examination of the chimneys structural and mechanical equipmentcomponents, accessories and appurtenances were also completed.

Evaluation of the significance of any detected degradation, deterioration, malfunction ordamage to the stacks, and their associated equipment systems, appurtenances or accessoriesand mechanical integrity were all completed within the inspection scope.

At this time we believe the chimney stack to be both structurally and mechanically sound. Thatis to say, it is able to perform its intended function of exhausting combustion byproducts me-

chanically and maintain its current configuration structurally for the foreseeable future barringacts of God type events outside of its original design parameters. There are, however, repairsthat need to be made in order to maintain the above status.

With the above statement in mind, the recommendations outlined in Section IX-Recommendations of this report should be addressed to acquire and insure the maximumpotential service life of the chimney stack as a structure.


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SECTION IIIntroduction

Industrial Access, Inc. was retained by Save The Stacks, LLC to conduct a mechanical condi-tion assessment of the Asarco 828 Smelter Stack at El Paso, TX. A comprehensive exteriorand interior inspection was performed at that time.

Based on the inspection findings, recommendations for repairs are mentioned and assigned acorrective action factor. The Action Items (AI) are classified into six (6) factors.

1A- Immediate concern or significant structural deficiency with imminent potential for lossof life, personal injury or structural failure of significance (potential forced outage).

1B- Immediate safety concern or significant non-structural deficiency with future potentialfor loss of life or personal injury.

2A- An examination scheduled as per the procedure guideline or sooner basedrecommendations made by plant observations or examinations.

2B- Moderate structural or non-structural deficiency which does not pose imminent potentialfor loss of life or structural collapse, but whose condition should either be corrected inthe near future or be closely monitored in the future for evidence of furtherdeterioration.

3A- Minor structural or non-structural deficiency which does not pose any threat to loss oflife or structural integrity. Functional defiance which may affect the structureperformance. Repairs are intended for better operation, maintenance. This priority willalso be used for identifying scheduled inspections.

3B- Non-structural deficiency which does not pose any threat to loss of life or structuralintegrity. Repairs are intended for better appearance.

Members of the Industrial Access Inspection Site Team were:

John Susong Project MangerBob Rielly Rope TechTommy Henderson Rope TechJohn Powell Rope TechVince Humble Robe Tech

This report presents our observations and together with our findings, conclusions,photographs, rehabilitation recommendations accompanied with recommended materialspecifications and pertinent publications.


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SECTION IIIStack Descriptions

Reinforced Concrete Column with Concrete Liner Constructed in 1966Wind load design 100MPH

Construction: 828 Concrete Reinforced Column 62 6od. Wall thickness at BOS 36TOS 9

Liner: 828 Concrete Reinforced Liner 200. Wall thickness BOS 36 TOS 10

Test Ports: Multiple Ports accessible @ 360 Personnel Platforms (3)

Platforms: (3) Full circumference platforms @ 800, 650, & 500 elevations.

LPS: Two Down-Lead System Grounding Stack. Air Terminals Mounted@ top of Concrete Stack

AWL: Triple Tier, Low Intensity Full Time Intermittent System @ 810 590AGL and Midpoint Platform

Ladder Irons: Steel Rungs with Safety Cage extending to the top segment of theConcrete Stack

Access Doors: 3x7 Door Accessible @ Base of Stack

Breeching: 2


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SECTION IVInspection Procedures

Upon arrival of our crew and equipment on the job site, personnel, ladders, scaffolding andsafety devices, all in strict accordance with OSHA and SPRAT safety regulations, were in-stalled to carry out the work.

The owner furnished 120 volts of power adjacent to the chimney termination for IndustrialAccess use.

After the inspection was completed, our crew removed all debris from the area and disposed ofthe 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 theconcrete column (windscreen). Our crew performed an exterior visual inspection of the Stack.This inspection examined the surface for cracks, corrosion and other anomalies. During theexterior inspection the test ports, walkways, access plates, etc. were also examined.

Photographs and documentation were taken at different locations depicting the conditionsfound.

Annulus Inspection

Industrial Access utilized rope access techniques to give access throughout the Annulus of theconcrete column and liner. Our crew performed an extensive Annulus visual inspection of theStack. This inspection examined the surfaces for cracks, corrosion and other anomalies. Dur-ing the Annulus inspection the test ports, walkways, access plates, etc. were also examined.

Photographs and documentation were taken at different locations depicting the conditionsfound.

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


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SECTION VStack 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 elevationand directional. The exterior inspection was done at 20ft intervals beginning at elevation 810ftAGL and ending at elevation 0ft. External Cracking and Spalling of the concrete shell wasfound 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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740 Elevation

720 Elevation

700 Elevation

680 Elevation

660 Elevation


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640 Elevation

620 Elevation

600 Elevation

580 Elevation

560 Elevation


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440 Elevation

420 Elevation

400 Elevation

380 Elevation

360 Elevation


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340 Elevation

320 Elevation

300 Elevation

280 Elevation

260 Elevation


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240 Elevation

220 Elevation

200 Elevation

180 Elevation

160 Elevation


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40 Elevation

20 Elevation


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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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Ladder System

670 Surface Cracks

660 Minor spalling and surface cracks

630

610


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Ladder System

590

570

550

530 Structural Bolts/Hardware need coating


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Exterior Conclusions

Schmidt Hammer Testing Results of the Exterior Concrete Stack are documented below.

Elevation (ft) North (psi) East (psi) South (psi) West (psi)

810 4500 4300 4200 4100

800 4500 4500 4600 4500

780 4400 4600 4400 4600

760 4400 4200 4400 4600

740 4400 4600 4000 4200

720 4400 4600 4400 4000

700 4600 4200 4000 4200

680 4600 4400 4000 4200

660 4900 4600 3800 4000

640 4600 4900 4000 4200

620 4600 4000 4000 3800

600 5000 4800 4400 4200

580 4600 5000 4000 3600

560 4200 4400 4000 4000

540 4800 5000 3800 4200

520 4800 4800 4200 4000

500 4100 4200 4400 4400

480 4800 4800 3800 4000

460 4600 4400 4200 4000

440 4800 4600 4000 3800

420 4200 4600 4600 4400


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Elevation (ft) North (psi) East (psi) South (psi) West (psi)

400 4600 4800 4200 4500

380 4600 4600 4400 4200

360 4800 4600 4200 4000

340 4800 5000 4000 4200

320 4600 4800 4400 4200

300 4600 4400 4200 4400

280 4400 4400 4000 4500

260 5000 4600 4400 4500

240 4800 4800 4200 4400

220 4900 4600 4000 4200

200 4600 4800 4400 4600

180 4800 4600 4600 4400

160 4600 4400 4200 4000

140 4800 4800 3800 3800

120 4400 4800 4400 4500

100 5000 4400 4200 4000

80 4600 4800 4400 4800

60 4600 4800 4200 4600

40 4000 4400 3800 4600

20 4400 5000 4000 4200

Exterior Conclusions

Schmidt Hammer Testing Results (continued)


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Ladder System

400 Needs Coating

380

360


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Ladder System

340

320

300 Missing Structural Bolts


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Ladder System

280

260

240

220 Loose Structural Bolts


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Ladder System

200 Loose Structural Bolts

160

160 Oxidation Present

140


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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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Aviation Warning Light (AWL) System

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


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Personnel Platforms & Structural Supports

650 Personnel Platform Needs Coating

500 Personnel Platform


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800 Structural Supports of Personnel Platform




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420 Rest Platform /Oxidation Present

200 Rest Platform


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Lightning Protection (LPS) System

LPS surrounding the Cap of the Stack with Lightning Rods

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


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Lightning Protection (LPS) System

LPS Grounding Connections

CAP

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


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Cap

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


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Test Ports

Test Ports Accessible via Personnel Platforms


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SECTION VIStack Annulus Inspection

Annulus

The following documentation was collected in the Annulus of the Stack. Industrial Access util-ized Rope Access Techniques to Inspect the current condition of the Inner Wind Screen andouter 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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Annulus

500 Elevation

450 Elevation

400 Elevation


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Annulus

350 Elevation

300 Elevation

250 Elevation


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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 associ-

ated with the Annulus Space. No thermal cracks were found in the liner,


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Section VIIIRecommendations

Based on the Inspections findings, the following recommendations for the maintenance and re-

pair of the 828 Concrete Stack are submitted. Please see Section II forAction Item (IA) Classifica-

tions.

Exterior:

(1A) Remove existing Cap and Structural Steel

Install New Custom Cap

(1B) Replace Sections of LPS that are Heavily corroded or broken.

(2A) 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

(2B) Strip and Tool Clean Exterior Concrete WindScreen

Hydroblast Concrete WindscreenInject Concrete Epoxy to Cracking and Spalling sections as needed

Apply Tnemec Primer and 2 Coats of Tnemec Coating to Concrete Windscreen

(2B) Tool Clean Personnel Platforms and Safety Rails

Apply Tnemec Primer and 2 Coats of Tnemec Coating to Steel Structures

(2B) Repair/Replace AWS Electrical Conduit and Wiring in Damaged areas of Corrosion

(3A) Lower interior liner to level of outside wind screen

(3A) Prepare and Carbon fiber Wrap top 40 of stack

These recommendations should be addressed in a timely manner to avoid further loss of structural integ-

rity and mitigate Immediate Safety Hazards.

hkn asarco stack report

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