The ability to address start-up risks to mineral processing facility in care and maintenance and move smoothly into production can be achieved through the adoption of operations readiness and restart activities as a key function and through a transition team engagement into the initial phase of a facilities operation.

Sedgman can offer operations readiness and restart services to operations and provide a transition team to commence operations, with a structured handover to your workforce after a defined term.

Our team has experience in successfully delivering this service having operated and transitioned a number of Coal operations, Crushing and Screening operations, as well as a Zinc Concentrator facility back to the respective clients. We have also been involved in a number of restart studies including:

A Copper concentrator in Tasmania, Australia
A Coal Handling and Preparation Plant in Central Queensland, Australia
A Gold Concentrator in British Columbia, Canada
A Ngangaju Lithium Concentrator in Western Australia

The key objectives of the operations readiness and restart program include:

Inspect the facility to identify pre-start maintenance activities, and estimate costs
Establish a master start up program
Facilitate, co-ordinate and undertake the above restart activities
Review and ensure that all the appropriate systems, procedures, and information requirements are in place and can be effectively used by site teams
Undertake mobilisation tasks
Provide a core of experienced Sedgman personnel to assist the client with production, training, and transition activities

Facility Inspection

As part of the phased approach to transitioning from care and maintenance to operations, the first step is to conduct a condition-based facility inspection on process plant and equipment (non-operational). This will focus on the following:

Structural, mechanical, and electrical defects that may affect start-up
Recertification of classified Plant
Identification of unsafe and/or non-compliant areas
Preparing a cost estimate to bring the facility up to standard for operations
The development of a comprehensive prestart maintenance plan

Maintenance Activities

After the initial inspection and cost estimate exercise, we can conduct all refurbishment activities including:

Physical inspection and non-destructive testing (NDT) of all critical equipment
Repair of any defects impacting safety and/or initial production
Undertake electrical works – statutory obligations
Recertification of classified plant

Operational Readiness

We can support your plant’s operational readiness by reviewing and developing the following:

Safety plans and systems required for operations
Mill and concentrator operations plans and procedures
Mill and concentrator maintenance plans and procedures, including: Maintenance shutdown strategy for the facility, Preventative maintenance schedule/strategy for concentrator equipment, and Condition monitoring and lubrication routines and schedules
Strategic and critical spares analysis to review stock holding
Sampling and analysis regimes
Radiation source management procedures
Logistics and procurement chains for key operational requirements
Training documents and materials for operational staff.

Mobilisation Tasks

We can assist your facility with the following mobilisation activities:

Conducting and documenting risk assessments that demonstrate operations will be performed such that risks are reduced to an acceptable level, and activities are compliant with industry standards
Implementing safety plans and systems required for operations
Recruitment of labour necessary for operations
Planning, procuring, and organising all plant, tools, materials, equipment, IT equipment, facilities and personnel required to undertake the services
Stocking of process consumables
Loading, transport and unloading of all plant, tools, materials, equipment, facilities, and personnel to site
Hire of any plant, tools, facilities, or materials necessary to commence operations

Operations Transition

A key aspect of any transition from a restart project into operations is to have skilled personnel on site, preferably during or just prior to the commissioning stage so that they may gain practical experience before the operational ramp-up. We can support your operations with the short-term provision of operations personnel to assist with commissioning start-up activities including:

Concentrator/Plant Manager/Superintendent
Metallurgist/Process Engineer
Maintenance Engineer
Electrical and Controls Engineer
Training Officer
Operations Front Line Personnel – Operator/Maintainers

All transition team members are highly experienced with key knowledge in the day-to-day running of processing plants, including proficiency in:

Continuous operation of all areas of minerals processing including comminution and concentrator circuits
Standard operational tasks, maintenance, and preventative maintenance
Developing process solutions to increase production and decrease downtime
Providing on-the-job practical training and assessment for our client’s teams
Commissioning assistance and planning

Sedgman possesses a large operations team able to offer off-site operational support including:

Metallurgists and Process Engineers
Health, safety, environment, community, and training (HSEC&T) professionals
Mechanical Engineers
Maintenance and Reliability Engineers
Electrical and Controls Engineers
Condition Monitoring professionals