Client: Rio Tinto Alcan (Gove Operations)
1. Project Background
Rio Tinto Alcan (Gove Operations) engaged CMP Engineers to investigate a fractured conveyor drum shaft at their Nhulunbuy facility. CMP Engineers were engaged to undertake a detailed fatigue analysis to determine the root cause of the failure and to inform future design and maintenance strategies.
2. Challenge
The fractured shaft posed a significant operational risk, potentially impacting production and safety. The challenge was to accurately model the fatigue behaviour of the shaft under operational loads and identify contributing factors to the failure. Constraints included limited access to historical load data, the need for rapid turnaround, and the requirement to deliver findings in a format suitable for both engineering and management review.
3.Solution
CMP Engineers conducted a comprehensive fatigue analysis, including:
- Data Review: Assessed available operational and design data to reconstruct loading conditions.
- Modelling: Applied advanced fatigue modelling techniques to simulate stress cycles and identify failure points.
- Reporting: Delivered a detailed engineering report outlining the analysis, findings, and recommendations.
- Costing and Risk Assessment: Supported the project with costing documentation and a design safety risk assessment to ensure compliance and inform future mitigation strategies.
4. Outcomes
Tangible Results:
- Provided Rio Tinto Alcan with a clear understanding of the failure mechanism.
- Enabled informed decisions on shaft redesign and maintenance planning.
- Delivered professional documentation including invoice, costing breakdown, and risk assessment.
Intangible Results:
- Strengthened CMP Engineers’ relationship with Rio Tinto Alcan through responsive and high-quality service.
- Reinforced CMP’s reputation for delivering technically sound and timely engineering solutions.
Key Learnings:
- Early identification of fatigue risks can prevent costly failures.
- Clear communication of technical findings is essential for client decision-making.
Intangible Results:
- The project was executed to satisfaction, with professional fees and deliverables aligned to the quoted scope.