SIMULTANEOUS RELINE – CASE STUDY

CASE STUDY
PROJECT / SIMULTANEOUS RELINE OF SIX MILLS.
MILESTONES / COMPLETED WITHIN STRICT DEADLINES IN HARSH CONDITIONS WITH ZERO DOWNTIME OR HARM AT NUI PHAO PROJECT.
MILLS INVOVED / BISMUTH MILL, COPPER MILL, FLUORITE MILL, ROD MILLS 1, 2 & 3.
PROJECT OVERVIEW
CLIENT / MASAN RESOURCES.
SITE / NUI PHAO, VIETNAM.
YEAR / 2016.
APPLICATION
CHALLENGE / SIMULTANEOUS RELINE ACROSS A HEXAD OF MILLS.
RELINE AND SHUTDOWN WORKS COMPLETED ON SAME TIMELINE.
CRITICAL PATH OF SHUTDOWN.
NO RELINE MACHINE ON SITE.
SOLUTION / SPECIALISED PERSONNEL PERFORMED MILL RELINE.
CRITICAL PATH MAPPING FOR ALL CONTRACTORS – ENSURING AWARENESS OF COMPLETE SHUTDOWN REQUIREMENTS.
RESULT / RELINE COMPLETED AHEAD OF SHUTDOWN.
COMPLETED WITHIN BUDGETARY LIMITS.
ZERO DOWNTIME WITH RELINE CREW AND ZERO HARM OCCURING THROUGHOUT ENTIRE SHUTDOWN PERIOD.
SPECIFICS
Located in the north west of Vietnam in rough terrain jungle, the Nui Phao project is a polymetallic deposit, with an initial Ore Reserve of 53Mt. The site has been defined to contain; tungsten, fluorite, bismuth and copper mineralisation. Mine production is designed to produce 3.5 Mtpa of ore for a multistream processing plant - The mine is a leading global producer of tungsten and acid-grade fluorspar. The site is a Fly-in / Fly out operation employing over 2,000 employees, contractors and local personnel.
Nui Phao contracted the expert services of IMR to perform coinciding six mill shutdown over a stringent period of four consecutive days. The Reline was scheduled to be performed in line with alternative contractors as a part of a site wide shut down for maintenance – however, the reline was deemed the critical path to all other shutdown services taking place.
As the mill liners and mill installation had been completed by our personnel initially since the sites establishment, the technically skilled and experienced team were aware of mechanical specifications, site complications and possible risks involved. The prior knowledge of the site and technical skills of the IMR team ensured they had a strategic approach implemented for the challenging task ahead.
Following a site conducted assessment of the mills, anticipated scope details were advised to the IMR team for consult and calculated project timeframes. However, upon inspection of the mills on set-up commencement, it was identified that additional works would need to be completed to extend the life of the mills until the next scheduled maintenance, ensuring the clients processing downtimes were minimized and on track for their processing projections. Our personnel were able to identify, plan, and implement a design solution within twenty-four hours of full inspection to ensure the mill would meet the next maintenance shutdown, as the original scope would have the mills worn before this period.
Once established, and all involved contractors, site representatives and IMR employees were informed of the change in scope, the reline commenced without hesitation. A team of 16 thoroughly trained and experienced personnel were on the ground as a part of the reline works across the six mills over a 24 hour operating schedule. The reline works involved over 1200 parts to be changed out, which attributed to the following successfully completed scope:
RELINE SCOPE
ROD MILL 1 / REMOVAL AND REPLACEMENT OF ALL SHELL LINERS, FEED AND DISCHARGE OUTER LINERS.
ROD MILL 2 / COMPLETE RELINE WITH ADDITIONAL SCOPE IDENTIFIED WITH EXTENSIVE BACKING RUBBER REPAIRS COMPLETED.
ROD MILL 3 / REMOVAL AND REPLACEMENT OF ALL SHELL LINERS.
BISMUTH MILL / REMOVAL AND REPLACEMENT OF ALL LINERS.
COPPER MILL / REMOVAL AND REPLACEMENT OF LINERS IN ALL SECTIONS.
FLUORITE MILL / REMOVAL AND REPLACEMENT OF LINERS IN ALL SECTIONS.
Many factors contributed to the exceedingly impressive results delivered by IMR. Though what has been critical to the success of this particular project is the qualified specialists that have worked collectively over decades. The accumulated wealth of; quality workmanship, knowledge, experience, education and the assistance of purpose designed equipment manufactured by IMR tradesmen to the sites specifications - Resulting in reduced reline time, all while maintaining the highest degree of safety.
The project seen managers, coordinators and supervisors work closely with the client to manage and maintain the critical path – ensuring the reduced downtime was a focal point for all involved. Though the project was not without its challenges, quality expertise and a precise approach in planning, monitoring and evaluation of the shutdown requirements ensured the completion of reline tasks would be ahead of schedule. The technical schedule of the reline included analysis and tracking of parts moved, time lost/gained, updated completion times and cross schedule comparison with all mills progress, allowing the team to manoeuvre manpower to other mills to ensure any delays or time lost/gained was considered, ensuring an accurate completion time across all mills was achieved.
The team have worked across a complete range of mills and lining formations which contributes to knowledge of all things mills that creates an environment where anything is possible when IMR are contracted. This level of service minimises any challenge restraints that were involved in the simultaneous reline, although, no project is challenge proof. While the relines were being carried out, the mill deck was subjected to high foot traffic and equipment congestion. Further challenges involved utilising local personnel, working alongside outside foreign contractors, strict deadlines and budgetary constraints. All factors contributed to a high risk environment, as such, it was critical to ensure that strict safety standards, legal obligations and performance standards were adhered to with all involved. Health and safety is the first and foremost objective of any project and mill reline. The IMR team ensured these standards were maintained and exceeded at all times with safety inspections conducted before and after each shift, in-depth discussion of safety performances and closely monitoring the shutdown stages and all contractors. The successful completion that was well under scheduled downtime with zero incident or injury is a testament to the IMR team, the service they deliver and their primary focus on safety.
RESULTS
With a strong results driven approach, the IMR team in conjunction with external contractors and the client, were able to complete a six mill reline ahead of the shutdown schedule. This outcome was able to attribute to maintaining and completing contracted works well under budgetary requirements and assisting in additional processing times on mill start-up. Ensuring projected processing targets would be achieved by the client, if not surpassed. The zero injury and incident project seen IMR complete another project with no lost time, injury, incident or service implications, which ensures the client meets their own safety, health standards and legal obligations.
Response from site and corporate representatives were positive and resulted in IMR attaining the complete mill maintenance contract with additional manufacturing components. This outcome has been one of which IMR are proud, and a milestone that has seen the company excel in exampling the technical skill, experience, knowledge and high quality services clients receive when employing IMR to complete their mill reline, mine services and equipment requirements.

Please direct any general / services enquiries to:

Andre Cuthbertson – Managing Director