Three dimensional animations integrated into a process plant computer-based training program can greatly enhance trainee understanding of process equipment. This is an example of an animation used as part of an overall training program for a plant that uses an air-swept vertical roller mill. This type of mill is typically used in cement plants. Para ver este video en español, haga clic aquí.

This video provides an example of the content and structure of a Performance Associates International computer-based operator training program. In this video, we focus on the user experience of our eLearning module for operators in a gold mill grinding circuit. This example demonstrates the following program features: • Language toggle controls. • Interactive process flowsheets. • Process descriptions. • Principles of operation. • Workbook feature. • Equipment (SAG mill) 3D animation. • Process variables. • Control loops. • Interlocks. • Alarms. • Interactive plot plan. The grinding circuit is just one of 11 modules included in the complete plant operator training program. Each individual module covers the technical aspects of a specific plant area. The program also contains modules presenting basic introductions to many applicable unit operations and a variety of basic mechanical skills. Additionally, detailed maintenance training modules cover each significant piece of equipment in the plant. A comprehensive training component to develop supervisory skills is included as well. Building, running, and maintaining a new plant is a significant investment. A work-force well-trained from top to bottom is the best way to protect that investment by ensuring a successful start-up and continued operations at peak performance. If you are building a plant and preparing your operators and supervisors for start-up and operation, please stop and ask the question “what components of this training program do I NOT want my operations team to be thoroughly familiar with?”

Although many mines and processing plants have sophisticated maintenance cost information systems, cost control relies ultimately on management actions based on the information such systems generate. A systematic management approach to solving problems and implementing solutions is the key to effective maintenance cost control

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom interactive modules have improved start-up success and operations for hundreds of clients on nearly every continent. In this training module, we cover how activated carbon is used to concentrate gold and silver from pregnant leach solution. The concentrating process is based on the concept of adsorption, in which complex gold, silver, and (if present) mercury molecules are adsorbed—or adhered—onto small, millimeter sized particles of activated carbon. The adsorption process is carried out at atmospheric temperature and pressure. During the process, the metals migrate from a cyanide leach solution to the surfaces of carbon pores. In addition to the animation, this module includes an animated process flowsheet, process variable target ranges and control methods, as well as alarm response procedures. This module covers one area of a gold ore processing plant. In a typical plant of this type, there would be another 4 to 8 modules that would cover the other plant areas with each module containing the same type of training materials, but specific to that plant area. In the training environment, some concepts are difficult to explain using still 2-D or even 3-D images. When this is the case, we develop animations and/or simulations in order to ensure better transfer of knowledge to our trainees.

Effective plant-specific computer-based training (CBT) used in a formal training program can make the difference between a successful start-up and a failure. Or, in the case of an existing plant, it can make a huge difference in the effectiveness of operating results—particularly if turnover of experienced personnel is a factor. Once the plant process design and control strategies have been established, equipment has been ordered, and the plant is either operating or under construction, the only major variable affecting success is the capability of plant operating personnel. It is essential that the myriad details concerning plant operation are documented in a comprehensive CBT system suitable for training the non-technical personnel who will operate the plant.

In this training module, Performance Associates International (PAI) covers the characteristics of a gyratory crusher that’s designed to be the first stage in the size reduction of run-of-mine ore. A gyratory crusher receives ore from a mine and crushes the ore between a gyrating main shaft and stationary liners called concaves. This module explains the gyratory crusher’s principle of operation and provides detailed descriptions of the major components and the role that each component plays in its operation. You'll learn how the drive system operates, the details of the dust sealing system, the importance of the various lubrication systems, and the two functions of the main shaft positioning system, or MPS. We’ll also explain the operation of the balance cylinders and how they’re designed to prevent oversize boulders from causing damage. We’ll also cover the apron feeder, which conveys the crushed ore from the crusher to a downstream discharge conveyor belt. The principle of operation and detailed descriptions of the components of the apron feeder—including the drive chains, pans, rollers, and an electric or hydraulic motor—are illustrated. This is one of many plant area modules that is covered in a typical PAI operations training module.

What would it mean to your process if the variation in your key process variables could be cut in half? For example, consider greatly reduced variation in: • Leach circuit pH. • Thickener flocculant concentration. • CIL circuit cyanide concentration. • Cyclone feed density. Do your operators know if variation is random or non-random? If your operators were more familiar with the process control methodology, would it make a difference? What would be the result if your operators could troubleshoot and optimize each process control loop? At Performance Associates International (PAI) we believe that if the process variables in the plant are controlled at or very near their individual target ranges, the plant should be operating at near optimal efficiency. This translates into the lowest operating cost per unit production. This white paper describes how PAI approaches this component of training for your specific plant. We train on your process variables, their target ranges, the method of controlling those process variables, as well as the impact on the process if the process variables are not properly controlled.

Far too often, natural resource companies start up new plants without a properly trained operations and maintenance team. The results can be disastrous for both safety and revenue. Obviously the ultimate objective is a plant that operates in a safe and profitable manner. In most cases, the pre-start-up safety training is satisfactory, resulting in few if any accidents during start-up and ongoing operations. However, many plants drop the ball when it comes to properly training operations and maintenance personnel. The payback on a properly executed training program far outweighs the cost. If you are going to budget for high-quality engineering, efficient procurement, and experienced and proven construction management (including commissioning), why leave training open to chance? Performance Associates International (PAI) developed an extensive operations and maintenance training program for Torex Gold’s El Limón-Guajes project in the state of Guerrero, Mexico. In 2015, PAI industry training specialists traveled to the project site to carry out the training for Torex Gold employees in anticipation of plant start-up and gold production. The venture was a “massive success,” according to Nelson Bodnarchuk, Director, Operational Systems. This video tells the story of that success, including generous feedback from the executive officers at Torex recognizing our role in the partnership.

Con demasiada frecuencia, las compañías de recursos naturales ponen en marcha plantas nuevas sin contar con un equipo de operaciones y mantenimiento debidamente capacitado. El resultado puede ser desastroso tanto en términos de seguridad como de ingresos. Obviamente el objetivo fundamental es una planta que funciona de forma segura y rentable. En la mayoría de los casos, la capacitación sobre seguridad que se da antes del arranque de la planta es satisfactoria, resultando en pocos accidentes (o ninguno) durante la puesta en marcha y operaciones subsecuentes. Sin embargo, muchas plantas son negligentes cuando se trata de la buena capacitación de su personal de operaciones y mantenimiento. Un programa de capacitación bien ejecutado compensa con creces los costos de ejecución del mismo. Si se va a presupuestar una ingeniería de alta calidad, un proceso de adquisición eficiente y una gestión de construcción experimentada y comprobada (incluyendo el comisionamiento), ¿por qué dejar a la suerte la capacitación? Performance Associates International (PAI) desarrolló un programa de capacitación por computadora comprensivo, el cual abarca operaciones y mantenimiento, para su planta de oro El Limón-Guajes en el estado de Guerrero, México. En el 2015, los especialistas de capacitación industrial de PAI viajaron al lugar del proyecto para entrenar a los empleados de Torex Gold en anticipación de la puesta de marcha de la planta y la producción de oro. El emprendimiento fue un “éxito masivo,” según Nelson Bodnarchuk, Director, Sistemas Operacionales. Este video cuenta la historia de ese éxito, incluyendo comentarios generosos de los oficiales ejecutivos de Torex, quienes reconocen nuestro papel en la colaboración.

In many mine and plant operations, safety is looked upon as an extra layer of special attention placed above the operations management layer. But safety awareness must be built into the detailed operations and maintenance training on the equipment as well as on the process itself.  

Excellence in Mining, Process Plant, Maintenance, and Safety Training Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today. Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs. Services PAI Offers Plant Operator TrainingOur three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations. Maintenance TrainingWe custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems. Mobile Equipment Operator TrainingOur first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures.Commissioning and Start-UpWe can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up.Testing and Tracking SystemsWe can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance. Introductory and Safety TrainingOff-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses!E-Learning, Animations, and SimulationsOur interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios.Other ServicesWe also provide many services relevant to planning, analyzing, and evaluating process plants, including:·         Operations readiness plan.·         Planning studies.·         Quality management.·         Systems implementation.·         Statistical process control.·         Reliability-based asset management.·         Productive capacity studies.·         Surveys and needs analyses.·         Economic life analysis.·         Process control strategies and methods.·         Debottlenecking and process optimization.·         Spare parts inventory and analysis.·         Feasibility studies.·         Consulting assistance.Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning

Three dimensional animations integrated into a process plant computer-based training (CBT) program can greatly enhance trainee understanding of process equipment. This introductory maintenance manual and animation provides a narrative description of a jaw crusher’s location in the process, its function, components, and maintenance requirements. The animation introduces maintenance personnel to the jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up. www.perfnet.com 

Developing a profitable mining venture is no small matter. It requires enormous initial investments in research, construction, and equipment. But a mineral processing plant does not run itself. Even with the best equipment and good ore quality, optimal results are dependent upon keeping the process running smoothly, avoiding process upsets, maintaining process variables in the desired range, and minimizing breakdowns and downtime. A highly trained workforce is an essential element in a successful, and profitable, start-up. The knowledge and abilities of plant operators and maintenance personnel can make or break an operation. Trained operators know what to look for during preoperational and routine inspections, allowing maintenance tasks to be planned and unexpected costly breakdowns avoided. Trained operators know what variables exist at different stages in the process and how to make appropriate adjustments in real time. Trained maintenance personnel are well acquainted with the plant equipment, and maintenance planners can schedule work and maintain a spare parts inventory to minimize downtime. Additionally, new operations that train their workforce just prior to plant commissioning can utilize their operators in the commissioning process. Having been trained and gained field experience through plant commissioning, operators are ready to hit the ground running once feed is introduced. A faster ramp-up means more earnings, more quickly. The cost of developing a proper training program is a small percentage of the overall engineering, procurement, and construction budget but it constitutes a large percentage of the gains realized from a successful start-up and ramp-up to full production. Performance Associates International (PAI) has designed and presented custom training programs for operators and maintenance personnel in metallurgical plants around the world for over 35 years. We are proud to have been part of the successful start-ups at Lundin Mining’s Eagle Mine, Vale’s Voisey’s Bay project, and Torex Gold’s El Limon-Guajes project. Click Download to view the actual vs. projected start-up results from these three metallurgical plants that made use of PAI’s custom-built training programs and on-site training.

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model.  Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:Process objective of each process system, comprising a group of unit operations.Process objective of each unit operation.Process chemistry and the variables affecting it.Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.Plant control loops, interlocks, and alarms.Safety issues related to the process and control schemes.Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks.Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training. 

The geology report, feasibility study, and mine plan look great. Why do so many mining project start-ups fail to perform? Most mining companies put a great deal of emphasis on the nature of the reserve, the mine plan, the extraction process to be used, and the process plant design—obviously all very important. Even when large, highly regarded engineering, procurement, and construction firms develop the project, operating results are very often disappointing. In this paper, we explore the role of Operations Readiness on the financial impact of mining project start-ups. A relatively small investment in operations readiness produces a huge financial return. Many investment firms, as well as mining company senior executives, fail to consider this important factor in operating success.

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom training modules and on-site training have improved start-up success and operations for clients on nearly every continent. We invite you to experience one of our e-learning training modules. Here you will see a video demonstration of a sample principle of operation from an e-learning module. A principle of operation describes in detail how a piece of equipment or a process works. In this sample, you will learn about Jameson Cell flotation technology and how its design allows for more efficient mineral separation in a much smaller tank than traditional column and mechanical flotation cells. We describe in detail the key components of the Jameson Cell and the operating principles. At the end of the module, a test will help assess what you learned. In a full training program, test results can be recorded and tracked in an LMS. A principle of operation like this would be only one of many included with a full plant operations training program. Note: This is a sample and does not contain the Jameson Cell training module in its entirety. If you would like to try out this e-learning module, please contact Kenneth Slack at [email protected] or +1-520-544-2220.

In this interactive PDF, we talk about common training myths and our responses.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

Ensure that your plant has a good inventory of spare parts on hand by learning how to collect the data necessary to build your own spare parts inventory model.