Case Study - Tailings Slurry Pipeline Wear Monitoring

Project Overview

The project aimed to implement 2Censor Abrasive Wear Monitoring Sensors to enhance the monitoring and maintenance of a tailing’s slurry pipeline. The setup involved installing five 20-meter sections (totaling 100 meters) of 280mm PN25 HDPE pipe spools. The third pipe section in the 100-meter span was equipped with sensor probes installed in each quadrant of the pipe circumference. The goal was to extend the lifespan of the pipes, reduce costs, and prevent environmental incidents.

Installation and Monitoring

• Pipeline Configuration: Five 20-meter sections of 280mm PN25 HDPE pipes were installed in situ.
• Sensor Placement: The third pipe in the 100-meter section was fitted with sensor probes at strategic quadrants to monitor abrasive wear.
• Targeted Wear Area: Measurements focused on the area 300mm back from the flange, under the pipe. The flange causing turbulence inside the pipe creating a higher wear location
• Monitoring Strategy: Only one pipe section was directly monitored, with the third pipe rotation alarm applied to all five sections on the same schedule.
• Software Integration: The software was programmed to issue three rotation alerts, with the fourth alert signaling the need for pipe replacement. Rotation and replacement forecasts were set with an 8-week lead time, overlapping with two scheduled maintenance days.

Results

Operational Efficiency and Cost Savings

• Extended Pipe Lifespan: The monitoring system extended the pipe life from 6 months to 2 years. With rotating the pipe extending the life of thepipe.
• Cost Savings on Supply: The extended lifespan resulted in a savings of $1.5 million on supply expenses.
• Unplanned Outages: The proactive monitoring and maintenance schedule eliminated unplanned outages, saving an estimated $1.2 million annually based on the previous year's costs (calculated from 2 six-hour outages, accounting for tonnes per hour and sale cost per tonne).

Environmental Impact

• Zero Environmental Incidents: The timely rotation and replacement of pipes prevented any environmental failures.
• Avoided Rehabilitation Costs: By preventing pipe failures, the project avoided government-mandated rehabilitation and associated fines, though specific cost data is unavailable.

Conclusion

The implementation of the 2Censor Abrasive Wear Monitoring Sensors in the tailings slurry pipeline provided significant operational and financial benefits. The system's ability to extend the pipe lifespan, eliminate unplanned outages, and prevent environmental incidents underscores its value. The proactive maintenance approach, facilitated by advanced monitoring technology, resulted in substantial cost savings and enhanced operational reliability.

This case study highlights the importance of innovative monitoring solutions in maintaining critical infrastructure in the mining sector. The 2Censor system proved to be an effective tool in achieving these goals, setting a benchmark for similar applications in the industry.