Lyntas/mining_domain_knowledge_reference_dataset huggingface dataset:
Area: Minning Projects 
Project located in the northern region of the Kingdom, The site is situated 23km from Al Jalamid village and 20km inside the desert. Al Jalamid village is located between Ar'ar and Turaif, about 100km from Ar'ar. Site
location is 31° 30' 51.7&quot;N, 39° 57' 13.7&quot;E (WGS84)
This Project is to economically mine the Al Jalamid phosphate deposit at a rated capacity of 5.0 Mtpy of concentrate and produce 2.9 Mtpy of diammonium phosphate fertilizer (DAP)
The Al Jalamid phosphate deposit will be strip-mined and the ore processed in a beneficiation plant at Al
Jalamid. The phosphate concentrate will then be railed approximately 1200 Km to fertilizer production
facilities located at Ras Az Zawr, on the Arabian Gulf shoreline, 85 Km north of Al-Jubail
At the fertilizer complex at Ras Az Zawr, the phosphate concentrate will be processed to produce DAP, in an integrated fertilizer complex consisting three Sulphuric Acid plants, three Phosphoric Acid plants, one
Ammonia plant and three DAP plants and the related infrastructure to support these plants. Port facilities will
be constructed to ship the product to market.
Both the Al Jalamid mine site and the fertilizer complex at Ras Az Zawr are green field sites and will
therefore require significant infrastructure development, both of a social and industrial nature.
Area: Minning Projects 
The beneficiation plant will utilize the process developed by SAPC and refined by Litwin to produce 5.020 million tones per year (dry basis) of concentrated phosphate rock. The beneficiation process involves particle size reduction using crushers and rod mills followed by desliming, froth flotation to remove carbonates, concentrate dewatering, drying and storage, concentrate reclaim and rail load out, waste disposal, and process water recovery and distribution. Other facilities will include Power plant. Water and wastewater treatment facilities, maintenance shops, warehousing complex, Administrative offices and a Bachelors' Community.
Area: Minning Projects 
Trucks 
Komatsu 830E, 930E and 630E
930E and 630E - used for removal of overburden
630E  used to take ore to dump pad
Service intervals
250 Hr service  Service Sheet 
Change engine oil, radiator coolant samples
500 Hr
750 Hr
1000 Hr
1250 Hr
1500 Hr
1700 Hr
2000 Hr  Major Maintenance
Major equipment in the trucks, gear boxes, air cooling systems and hydraulic systems
Area: Minning Projects 
Electrical Shovels (Liebherr 996 , Komatsu & Hitachi)
Area: Minning Projects 
Wheel Loaders 
To be used in the dump pads
Caterpillar 992
Area: Minning Projects 
Excavators
Used for construction of roads and pits
Area: Minning Projects 
Water Carts
Used foe dust impressing
Area: Minning Projects 
Pit dewatering pumps
To evacuate pits during rainy season, Aker Wirth Pumps
Area: Minning Projects 
FIX PLANT
Bull Horn Crusher/ feeder and hopper arrangement 


Ore is fed into a Hopper and then transported to the crusher with the help of conveyors
There is a different control room for the crusher
Major reliability issues with bull Horn Crushers is,
Cracks in the Horns
Bondi  Product melt and become one product
Feeder is a critical equipment in the plant
Crusher maintenance  2 day / 5 Day
Pully system  bent up pully

Conveyors
Conveyor arrangement
Pulley vibration check  6 weeks
Lube Schedule  	take sample
		Check Oil Levels
		Greasing
		Thermography for bearing

PI Progress book
Normally the thermography is done in 4.30 am in the morning and put a tag, a note on a book and then create a WO (Work Order)
Belt Inspection
Every 3 months Planned shutdown ( 5 days )
Every 1 year MSD  June/Aug ( 8-12 days )
Area: Minning Projects 
Mine Fixed are is two parts
Dry Area
In a mine where there is crushing 
Wet Area
Grinding and rest
Area: Minning Projects 
Gyratory Crusher -> 2 X Cone Crusher ( Serial and no stand by crusher)  Banana Screen/ Vibratory Screen
During Grinding water is added to the system
Area: Minning Projects 
Reliability Issues 
Roller damage
Belt damage
Hopper liner worn and damage
Area: Minning Projects 
RCA Analysis
Power Plant  General 15 MW , Piston damage
/back pressure exhaust  Cracker muffler
Power plan is totally unmanned and have 5 engines = 3 (Run) + 2 (Standby)
Engine is 4.2 MW
Type of oil  320 or 220 oil
Area: Minning Projects 
SAG Mill	Grate Ball/SAG Mill
Liner replacement in a Shutdown, every 8  12 months
Ball feed conveyor 
Grate reliability Issue. The solution was
SWI  Standard Work Instructions
Check Hardness ( Hardness test Brinell hardness test)
QA assurance from supplier
Relining machine  Replace grates
Area: Minning Projects 
Mill Circuit
SAG Mill -> 2 X Ball Mills -> Cyclone Separator- Rotating Screens -> Slurry
The return line (Oversize) from Separate comes back to Ball Mills.
Ball Mill 
Rubber liners
Grates

Bolt Map  Check the bolts before going inside ball mill 
Broken bolt
Replace bolts
Go inside
Ball mills got 1 motor for inching
Area: Minning Projects 
Rotary Screens
The slurry goes to flotation circuit (70 tanks) add chemicals, (chemical circuits)
Blower plant is to air supply 3 X Blowers (Blower circuit)
IA (Instrument Air) Circuit
Area: Minning Projects 
Reliability Issues with Flotation Cells
Agitator bearing condition monitoring  Drive End bearing and non-drive end bearing
The blowing Circuit in the plant is a critical equipment
Area: Minning Projects 
Reliability Report
Current condition
Vibration condition
Area: Minning Projects 
Thickener
The overflow of the Thickner goes to process water dam 
Zn product tank X 3
Ld product tank X 2
Ld is goes to Lead Dam. 

Pump X 3 and Slurry pumped, to Filter Press X 4
Klinker is Diesel fired
(80m  90m) long
Area: Minning Projects 
Thickener Reliability Issues
Rake  Unbalance -> Damaged floor
Rake trip -> lift the rack and re-start

Rake balance during the SD using theodalight

Tailing Pump (Redundant System)
Tailing dam  Clay Lining / Geofabrication lining

Reliability Planning
Lube schedule
Lube sampling (Oil, Grease)
Lube analysis
Spare parts management

Kidney looping of gear boxes -> external filter cartridge (24 Hr)
Area: Minning Projects 
Integrating the project schedules
The rescue team had to create an integrated critical path schedule for completion of the project to integrate separate schedules for each of the three main contractors plus the detailed commissioning schedule and replace a separate summary schedule representing the project for use by the senior project management team.
Area: Minning Projects 
Concentrate tank upgrade 
The upgrade involved the design and construction of 2 large, and 2 smaller steel tanks. The large tanks are over 13m in height and have a storage capacity of over 120,000 litres of concentrate. This additional storage capacity will enable additional throughput of ore to China and increases the overall growth capacity of Newcrest.
Area: Minning Projects 
Weather challenges
Challenges facing the project team at Oyu Tolgoi included operating at 3,800 feet, extreme weather, and limited access to essential utilities and services. The Gobi Desert presented a brutally harsh environment, with temperatures ranging from -40 C to +45 C. The country is landlocked, with limited access via roads or rail.
The harsh environment demanded adaptation for typical project tasks. For example, in applying 145,000 cubic meters of concrete for the concentrator, the team used cold-weather techniques in order to pour concrete when it was -30 C. This included fabricating tented structures with diesel-fired heaters to keep the formwork and rebar at an acceptable temperature and to keep the freshly poured concrete from freezing.
Other project infrastructure included upgrading a 104-kilometer road from the Chinese border to the site; building a 1,000-liters-per-second pipeline from a borefield; 80 kilometers from the site; setting up housing facilities for more than 10,000 workers; and establishing 80 square kilometers of site development that included an airstrip, roads, concrete batch plants, water distribution systems, associated electrical power distribution, and two mining shafts 1,800 meters each in depth.
Area: Minning Projects 
PROMINENT HILL CHF PLANT UPGRADE, PROMINENT HILL MINE, SA
Under Contract to Outotec, this project was for the fabrication, surface treatment and delivery to site of various items required to complete the CHF Plant upgrade, including two tanks and a cyclone support structure.
Area: Minning Projects 
PASTE BACKFILL PLANT  XSTRATA ZINCE MINE MT ISA
Under contract to Outotec, this project was for the fabrication, delivery and construction of a Paste Backfill Plant at the Lady Loretta Zinc Mine in Mt Isa.
The project included: fabrication, delivery to site, structural, mechanical, and piping installation onsite for Xstrata Zinc which was completed in June 2013.
This also included all the electrical installation being completed by Stripes Electrical.
It included 5200m2 of steelwork for surface treatment. This was carried out using a 2 and 3 coat paint system. The steelwork included frames, conveyor sections, platforms, chutes, hoppers, tanks, stairs and handrails.
Area: Minning Projects 
SAG Mill commissioning
The milling circuit is predominantly refurbished and ready for operation with the new 3,000-tonne-per-day Semi-Autogenous-Grinding (SAG) mill installed and aligned (Figure 1). The two Ball Mills have been refurbished and will be available for commissioning following upcoming replacement of upgraded trunnion seals.
The Zinc and Lead flotation circuits and associated pumps have been refurbished or replaced and are ready for commissioning.
Area: Minning Projects 
SAG Mill Control
Modern plant control systems (PCS) whether Programmable Logic Controllers (PLC) or Distributed Control Systems (DCS), are extremely powerful process control and automation engines. In the mining industry these systems are used extensively for basic control functions,
SAG mill control fundamentally means managing the load in the mill by adjusting the feed rate of ore to the mill and/or manipulating the rotational speed of the mill. The best way to measure load is to mount the mill on load cells. The load cells are calibrated to measure the total weight of water, grinding media (balls) and ore in the mill, but not the weight of the mill itself. While many mills today are mounted on load cells, others employ bearing oil pressure as a proxy measurement of mill load.

A control strategy recently implemented on a large variable-speed SAG mill at MMGs Century Zinc operation in Australia is shown in the chart (found on pg. 32). In this case, mill speed is the primary manipulated variable used to control mill load.
Area: Minning Projects 
Mill Drives and Brakes Muscle Up
Recent years have seen a trend toward fewer comminution machines per process line, particularly as grinding mills have increased considerably in size. Today, autogenous grinding (AG) mills as large as 40-ft in diameter with motor power in excess of 20 MW are being ordered and installed as producers look for higher production and economy of scale in their process plants. Semiautogenous grinding (SAG) mills up to 44-ft diameter with 35-MW gearless mill drives (GMDs) are available.
These large, powerful gearless drive mills require improved control systems, ranging from the sophisticated controllers that monitor and protect the mills ringmotor and frequencyconversion electronics from electrical damage, to the braking systems that provide safe, controlled stops. And, as these larger units replace multiple smaller mills and are often installed at sites in remote locations.
Twiflex said its braking system is designed specifically for grinding mill installations and provides both static and dynamic braking functions. In static operation, the braking system holds the mill motionless during liner replacement and general mill maintenance. For dynamic operation, the system can operate in two modes, stopping the mill from full speed in an emergency or providing inching/creeping capability in the event of bearing lubrication problems or power failures.
Effective SAG mill control will maximise throughput, minimise damage to mill internals (liners and lifters) and contribute significantly to achieving maximum recovery in flotation. Well designed and implemented SAG control will payback in weeks not years. SAG mill control is essentially the stabilisation of mill load (and/or power) and density which can be implemented successfully and very cost-effectively on most modern PLC or DCS platforms
As an example, a few years ago the company assisted BHP Billiton at its Cannington silver, lead and zinc mine in Queensland to overcome problems that were being experienced with its autogenous mill. With mill overloading a major cause of plant downtime, the company used its Control Performance Optimizer to create a simulator that would give the mill staff a better understanding of their grinding circuit, as well as developing a mill charge-volume estimator to provide real-time feedback on the state of the mill.
According to Outotec, grinding circuit efficiency is key to improving the overall performance of a concentrator, so good grinding-circuit control is of major importance. This in turn relies on inputs such as dependable real-time particle-size information. The company has a long history of supplying PSI particle-size analyzers to help optimize grinding circuits, and more recently has built on this experience to provide advanced grinding-control solutions.
As an example, its PSI 300 is an on-line particle-size analyzer system for mineral slurries. Automatically taking samples from up to three process streams, it measures P40 to P90 particle size in the range of 251,000 µm (50015 mesh) as well as the sample density and pH
Area: Minning Projects 
Expert Control and Supervision
FLSmidths ECS/ProcessExpert control and supervision system provides advanced process control and optimization for minerals plants, including grinding circuits, by analyzing a wide range of signals and actuating automatic adjustments to manage the equipment and process performance. ECS/ProcessExpert measures the mill power consumption, load impacts, mill mass, sump levels, circuit flows, pump power, stream density, hydrocyclone pressure and product quality, using these data to control the feed rate, mill water addition, mill speed, cyclone feed density, pump speeds and circulating loads.
Area: Minning Projects 
Lihir gold mine
Projects include upgrading the electrical and control systems and replacing the neutralisation cyanidation adsorption (NCA) circuit. The expansion project of increasing the flotation capacity is proceeding on schedule to a July 2013 delivery.
Area: Minning Projects 
Belt Drive Issues
 Tension and alignment are shutdown jobs > at a minimum needs to be stopped and isolated.
 Symptoms ->  Noises coming from belt area, Drive rack or bridge vibration / wobble ,Motor noises, Heat
Area: Minning Projects 
Level Indicator
 Typical Issues ->  Shaft sticking, Ball sinking (or floating on froth), Not set-up properly, Reading incorrectly, Not calibrated, Not spanned correctly, Need to check regularly
 Is level control OK?
 Loops tuned, Valve positioners working?, Perhaps its the level indicator?
Area: Minning Projects 
Mt Isa Mine Copper Concentrator
The aim of the flotation capacity upgrade project was to improve copper plant recovery by approximately 2% through major brown fields work completed in two stages. This work included the installation of additional flotation equipment, pumps and pump boxes, lifting facilities, electrical supply, instrumentation, DCS upgrade, reagent distribution and process piping.
Area: Minning Projects 
Carbon in leach Plant
Double-impeller Leach Tank For Gold Cyinadation Process
The Telfer concentrator, located in the Great Sandy Desert of Western Australia, consists of a dual train gold/copper operation processing ore from one underground and, currently, two open pit mines with differing mineralogy. The fl otation circuit of each train was designed to operate in several modes depending on the feed mineralogy. The majority of ore mined at Telfer is processed in a sequential mode where copper minerals are first floated into a saleable copper concentrate followed by the flotation of an auriferous pyrite concentrate which is treated in an on-site hydrometallurgical plant (carbon-in-leach (CIL)). Gold is recovered as a gravity product within the primary grinding circuit, to the copper concentrate, and to a lesser extent, the CIL circuit.
Area: Minning Projects 
Copper Upgrade
Since Telfer was re-opened, with a new concentrator, in 2004, the processing plant has struggled with poor copper concentrate grades, partially due to the excessive entrainment of non-sulfide gangue minerals in the copper flotation circuit.
The equipment was kept to one area for ease of maintenance and also to minimise cost and disturbance to the running operation during construction and commissioning. The regrind mills share a common platform with a 10 t gantry crane overhead for ease of maintenance.
The major equipment was purchased directly from vendors by Newcrest Mining to reduce the time frame of the installation, and to allow a staged process of capital commitment during the project development phase. Process design and major equipment sizing was carried out by Newcrest Mining personnel (authors of this paper), and a third party engineering firm (GR Engineering Services Limited) was contracted under a lump sum EPC to complete the installation of the equipment.
Xstrata Technology supplied a vendor package containing the pyrite regrind mill (the copper mill was purchased from a third party as a second-hand unused mill), the mill platform to support both mills, feed and discharge hoppers, media handling systems and all associated instrumentation and steel work. ISAMillTM technology was chosen for the regrind duty due to their proven energu effi ciency and the inert grinding environment which prevents passivation of the sulphide surfaces (Pease et al, 2006). Several of the improvements outlined by Rule and de Waal (2011) were incorporated into the ISAMill confi guration). Outotec supplied the fl otation cells
(5 × OT30s) used in the pyrite regrind circuit which have been fi tted with Outotecs fl oat force mechanism (Coleman and Rinne, 2011) as well as high shear stators (Bilney, MacKinnon and Kok, 2006) to optimise the hydrodynamic conditions for fi ne particle fl otation.
The on-site construction period will total approximately 12 months
Area: Minning Projects 
pumps located on ground level for ease of maintenance. The additional cost of elevating the cells was offset by lower operating and maintenance costs than if tailings and concentrate pumps and hoppers had been required. The cells have eight downcomers each, and are each driven by a 75 kW Warman 10/8 pump with a recirculating slurry fl ow rate of approximately 700 m3 /h. The fresh feed rate to each Jameson cell is in the order of 175 - 350 m3 /h (or approximately 20 to 60 t/h solids). The washwater system was designed to achieve a fl ow rate of up to 100 m3 /h per cell.
Area: Minning Projects 
Improving gold extraction
Burns et al (2012) showed that the optimal approach to improving CIL performance (in terms of both improving recovery and reducing operating cost) was to install a regrind mill on the current CIL feed stream, and then remove liberated gold and copper particles by fl otation (pyrite recleaning) prior to leaching the fl otation tailings stream.
Area: Plant Integrity
Asset Integrity can be defined as the ability of an asset to perform its required function effectively and efficiently whilst protecting health, safety and the environment.
Asset Integrity Management is the means of ensuring that the people, systems, processes and resources that deliver integrity are in place, in use and will perform when required over the whole lifecycle of the asset.
Asset Integrity Management can further be described as the continuous assessment process applied throughout design, construction, installation and operations to assure that the facilities are and remain to be fit for purpose
Area: Plant Integrity
In this context integrity is defined as the prevention of the loss of containment of a fluid or energy from the facilities. The integrity management process covers the 
Equipment containing the fluid
 Structures that support the equipment
 Other systems that prevent, detect, control or mitigate, against a major accident hazard.
Area: Plant Integrity
A loss of integrity (containment) could have an adverse impact on the safety of personnel, on the safety of the asset / facilities, on the environment or on production and revenue.
Area: Plant Integrity
The aim of the asset integrity management process is to provide a framework for the following:
? Compliance with company standards, regulatory and legislative requirements
? Assurance of technical integrity by the application of risk based or risk informed engineering principles and techniques
? Delivery of the required safety, environmental and operational performance
? Retention of the License to Operate
? Optimization of the activities and the resources required to operate the facilities whilst maintaining system integrity
? Assurance of the facilities fitness for purpose
Area: Plant Integrity
There are a number of processes and activities, which are carried out by various bodies with the aim of ensuring that the overall integrity of the asset is maintained
Area: Plant Integrity
Design
The following is not an exhaustive list but the items in it should be considered during the design phase:
? Subsea Integrity Management Strategy (SIMS)
? Pipeline Integrity Management System (PIMS)
? Major Accident Prevention Document (MAPD)
? Emergency Response Procedures (ERP)
? Inspection, Maintenance and Repair Plans (IMR)
? Planned Maintenance Routines Plan (PMR)
? Hazop studies
? Dropped objects
Area: Plant Integrity
Operate
The following should be considered as fundamental to safe and efficient operations
? Commissioning requirement and report
? Update all the Integrity Documents (Design Phase)
? Risk Based Inspection/Maintenance analysis (RBI)
? Operation procedures
? Life extension studies (If required)
? Remaining life analysis
? Fitness for Service Assessment
Area: Plant Integrity
Maintain
When looking at developing optimum preventive and predictive maintenance programs there are a number of building blocks that need to be considered. These include:
Knowledge of failure aspects
Failure modes and their characteristics
Failure consequences
Failure mechanisms
Failure causes
Age-reliability characteristics

Knowledge of predictive tools / techniques
Vibration
Thermography
Eddy Current
Fibre Optics
Ultrasonics
Radiography

Knowledge of methods of analysis
Trending
Pattern recognition
Data comparison
Testing against limits and ranges
Statistical analysis
Area: Plant Integrity
Many industries are implementing ISO 55000 (formerly known as PAS 55) - Specification for the Optimized Management of Physical Assets - as a method to assess their Management Systems and compare them with other leaders in their industry. ISO 55000 defines an Asset Management System as incorporating the following requirements:
Area: Plant Integrity
Asset Integrity Management System Review
The following topics would be covered when auditing or reviewing a companys Asset Integrity Management system. Not all subjects would be applicable in every case. The following list is not meant to be exhaustive but merely a guide to areas of interest.
Area: Plant Integrity
COMPANY ASSET INTEGRITY POLICY
The provision of an Asset Integrity Management System and its financing
Definition of management responsibility & commitment throughout the company for Asset Integrity
Ownership and understanding of the systems arrangements with regard to employee communication, consultation and involvement in participation and implementation
Training and competence at all levels and duties of employees and contractors
Planning and setting of Asset Integrity objectives
Resources both human and system to implement the policy
Demonstration of continuous improvement