CV-005 TAIL PULLEY 13_CRACK PULLEY DRUM: FAILURE TIMELINE

02-15-CV-005 PULLEY # 13 (TAIL) FAILURE (CRACK DRUM) EVENT TIMELINE

Operator noted Shift Fitter sent to Belt noted to track on Inspected and noted
Contractor Operator Shift Supervisor OLC restored
4x Locking Pick up on call one side so notified Pulley # 13 with
stationed at Tail end prepared Paperwork back and started
Screws on Pulley Supervisor at Ridge CRO to hit “E” Stop. cracked drum
drive Station for possible shutdown. up Operations
broken Line
Information Source Information Source Information Source Information Source Information Source Information Source
Information Source
Ops Supervisor Statement Ops Supervisor Statement Ops Supervisor Statement Ops Supervisor Statement Ops Supervisor Statement Honeywell Downtime data
Ops Supervisor Statement
Photograph file, Visual

06/12/2020 06/12/2020 06/12/2020 06/12/2020 06/12/2020 06/12/2020 11/12/2020

20:45pm 20:50pm 19:00pm
20:10pm 20:12pm 20:15pm 20:20pm
 CV-005 TAIL DRIVE PULLEY 13_CRACK DRUM: RCA CAUSE & EFFECT SUMMARY
Lack of OEM CB Desired Condition
STOP Other Cause Path More effective
Design Data
CHART LEGEND CB Evidence:
Operating Beyond Full OEM Data Available
Desired Condition
Root Cause Design service life STOP
CB Other Cause Path More effective
CB
CB Evidence: Lack of Spare
Other Causes Not a Concern, Pulleys Pulley 2
Collapse in Belt CB
Operational CB
designed for infinite life CB
Evidence: Increase in Belt
Evidence Pipe cross STOP Desired Condition
Metal Fatigue Spare Pulley was Available Thickness Requirement Other Cause Path
CB section
Failure More effective
Evidence:
? More Information needed
Evidence: CB Increase Cyclic
Evidence:
Email - See Appendix F
Evidence:
Email - See Appendix F Email - See Appendix F

1 Go To related cause path

Email - See Appendix F Stress/loading
CB Increase in Tail pulley CB Go to
CB Evidence:
CB – Caused By Email - See Appendix F
tension by 9% 1 ..increase in Pulley Tension
CB Cyclic (T1/T2 = 390kN/370kN )
Stress/loading Evidence:
fluctuations Within Design Specification,
CB Decrease Cyclic <800tph. Honeywell Data
Evidence:
Email - See Appendix F Stress/loading
CB Desired Condition
118 Hours CV-005 Downtime Evidence: No Concern STOP Other Cause Path More effective
58kt ore deferred CB Tail Pulley 13
Go to
$2.4M Revenue deferred cracked drum CB Insufficient Take- CB ..increase in belt thickness
2
$44.8k repair cost up Tension
Tail Pulley Tension
Evidence:
Evidence:
Photograph/Visual increase by 9% Evidence:
CB Insufficient Take- CB
Honeywell report Email - See Appendix F Go to
(T1/T2 = 390kN/370kN) 2
up Tension ..increase in belt thickness
CB Evidence:
Email - See Appendix F CB Tension and Power Evidence:
1 Email - See Appendix F
Out of Spec.
CB Head Pulley Tension (330kN<390kN/370kN)
Increased Pulley CB
increase by 14% CB No Change in CB
Tension Evidence: OEM Data,
(T1/T2 = 300kN/100kN) Section 2.4.1.2, page 138. pulley design ? More Information Required
Evidence: Evidence: Awaiting Failed Pulley Test Results from ALS
Evidence:
Email - See Appendix F CB Email - See Appendix F
Tension and Power Email - See Appendix F
Increase in Belt within design spec. CB
Thickness STOP Desired Operating Condition
Evidence: OEM Data,
CB Evidence: Section 2.4.1.2, page 138.
Email - See Appendix F CB
2 Go to
..increase in belt thickness
Manufacturing CB Supplier oversight in CB
Defect manufacturing process ? More Information Required
Awaiting Failed Pulley Test Results from ALS
Evidence: No ??? Evidence: No ???