Application of the RCA (Root Cause Analysis) methodology in a pumping system of reverse osmosis treatment plant. Case study: Sanitary Sector (Distribution of water and treatment of wastewater).

Abstract

This study applies the Root Cause Analysis (RCA) methodology to the high-pressure pumping system of a modular reverse osmosis plant used for the treatment of deep-well water for sanitary purposes. The analysis identifies recurrent failure modes in the subsystems of prefilters, multistage centrifugal pump, motor, and control, leading to pressure losses, unplanned shutdowns, and variability in process performance. The main contributing factors include cavitation, accelerated fouling of the filter cartridge, operational deviations, and deficiencies in the installation of mechanical components. Through functional diagnostics and analysis of probable causes, failure modes are prioritized using the concept of Annualized Total Risk (ATR), allowing the development of corrective actions aimed at improving operational reliability, reducing operational risk, and ensuring the continuity of the reverse osmosis process in the sanitary industry.

 The article describes and analyzes the following:

·        The study identifies and prioritizes the most critical failure modes of the high-pressure pumping system through the Annualized Total Risk (ATR), determining that the Clogged Cartridge mode acts as the dominant operational root cause by triggering subsequent hydraulic and electrical failures in the multistage pump and motor.

·        The Root Cause Analysis (RCA) methodology is applied following the Parra & Crespo model, integrating a multidisciplinary team, defining the problem, validating evidence-based hypotheses, and classifying physical, human, and latent causes to understand the systemic behavior of the asset.

·        The analysis proposes corrective and preventive actions aimed at eliminating or mitigating validated root causes, including the standardization of procedures, technical training for personnel, the establishment of condition-based replacement criteria, and the creation of a corporate filtration standard to improve hydraulic stability.

 Finally, the implementation of these measures projects a reduction of ATR from $58,441,866 CLP to $2,177,500 CLP, demonstrating a significant decrease in operational risk, greater continuity of the reverse osmosis process, and a substantial improvement in system reliability and availability.