Root Cause Analysis – Premature Spool Wear in a Heat Sink Station

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Root Cause Analysis – Premature Spool Wear in Dissipation Station

Peru, 2024

The main objective of the project was to investigate the accelerated wear and cracking events that occurred in the dissipation station of the Toromocho Mining Unit's Tailings Transport System. As a result of the analysis, recommendations were formulated to strengthen the Pipeline Integrity Management System, implement quality controls in the acquisition and manufacture of special parts, update the hydraulic models (Steady State) with current rheological conditions, and conduct failure tests (expert analysis) on the removed components to confirm the hypotheses. It is also suggested that dynamic flexibility analyses be performed and the correct installation of anti-vibration mounts be verified on-site to prevent future events that could compromise operational continuity and the safety of the facilities.

Key aspects of the design carried out

Application of Logical Fault Tree Methodology for Root Cause Identification

The analysis was structured using a rigorous fault tree methodology, which allowed each event to be systematically broken down into progressive levels of causality.

CFD Modeling as a Tool for Validating Hydraulic Hypotheses

The hypothesis of preferential flow due to insufficient stabilization distance between the change of direction and the dissipating ring was validated by computational fluid dynamics (CFD) simulation.

Detection of Gaps in Manufacturing Quality Traceability

During the review of the quality dossier, the absence of the materials certificate that accredits compliance with the technical specifications was evident.

Key aspects of the design carried out

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