Reliat
INC-26-0417 oversize bypass
ROOT-CAUSE INTELLIGENCE · BULK MATERIAL

One oversize event,
followed all the way
through the plant.

Reliat watches every particle on the belt, reconstructs what happened, and traces it downstream — before it becomes a trip, a spec breach, or a shift of lost throughput.

PHASE 01 · DETECTION

Every particle,
measured on the belt.

An optical plane sweeps the moving stream. No sampling, no lab delay — the full flow is scanned as it passes, particle by particle.

LINE · PRIMARY CRUSH A
MATERIAL · CRUSHED BASALT
BELT · 2.4 m/s · 820 t/h
PHASE 01 · RESOLUTION

Material becomes a
size distribution.

Each scanned fragment lands in its size band. What was rock is now a live particle-size distribution — measured against the control limits for this product.

ANOMALY DETECTED

Oversize, past the
upper control limit.

A sustained tail above 90 mm — material that should never leave the crushing circuit. Eleven consecutive readings breach the USL.

EVENT BOUNDED
14:23:06 → 14:24:51
105 s

Onset and recovery pinned to the second — the exact window the rest of the analysis is built on.

PHASE 01 · EVIDENCE

The evidence
assembles itself.

One event. Five independent signals.
Read together, they describe a single material path.
INCIDENTINC-26-0417
CORRELATION WINDOW105 S
SIGNALS ALIGNED05 / 05
EVENT PATH CONFIRMED
01 / STATISTICAL PRIMARY SIGNAL
P80 particle size
96mm +128%
BASELINE42 mm UPPER SPECIFICATION90 mm
02 / CONTROL RULEWE RULE 1
Points beyond USL
consecutive observations
11points
03 / MASS BALANCEFLOW
Oversize to mill feed
vs. recirculation baseline
+6.1t/h
04 / PHYSICS+1M 47S
Mill power draw
correlated downstream response
+140kW
05 / CONTROLEXCLUSION
Belt speed
rules out throughput artifact
2.4m/s · flat
PHASE 01 · ROOT CAUSE

Ranked by evidence,
not intuition.

Each explanation is tested against the same event record.
Support, conflict, and uncertainty stay visible.
ASSESSMENTINC-26-0417 / RC-01
BASIS05 ALIGNED SIGNALS
STATUSPROVISIONAL
NEXT BEST CHECKCSS CALIBRATION LOG
RANK01LEADING
Crusher CSS drift

Closed-side setting opened, allowing oversize material through the crush zone.

CONFIDENCE0.72
SUPPORTING · 03

Motor amps ↓ 8%
P80 rise matches setting gap
Localized to deck 2

CONTRADICTING · 01

No liner-wear alarm

MISSING · 01

Last CSS calibration log

72%BEST FIT
RANK02ALTERNATE
Screen panel failure

A torn deck panel passing oversize directly to product.

CONFIDENCE0.19
SUPPORTING · 01

Bypass on one deck

CONTRADICTING · 02

Even size across width
No inrush on screen motor

MISSING · 01

Deck camera frame

19%LOW FIT
RANK03ALTERNATE
Feed surge / segregation

A momentary feed spike overwhelming the crush zone.

CONFIDENCE0.09
SUPPORTING · 01

Feeder speed spike at 14:22

CONTRADICTING · 02

Size sustained past surge
No level drop in bin

MISSING · 01

Feed hopper level trace

09%LOW FIT
PHASE 02 · PROPAGATION

The same event,
traced through the plant.

INCIDENT TRACE · INC-26-0417 105 S CAPTURE · 5 LINKED SYSTEMS
PROCESS PATH / PRIMARY CRUSH A
EVENT PATH NOMINAL RECIRCULATION
ARRIVAL / ELAPSED
Crusher CR-01t0 Conveyor CV-02+38 s Screen SC-01+52 s Mill ML-01+1m 47s
EXPOSED ASSETS
01ML-01 liners
02ML-01 cyclone
03Load-out specification
ENGINEERING NOTE
Mill overload risk inside four minutes. Liner wear accelerates; load-out specification is exposed if the event is not corrected.
THE INCIDENT ARTIFACT
INC-26-0417
Oversize bypass — Primary Crush A
14:23:06 → 14:24:51 · 105 s
Root cause · Crusher CSS drift · 0.72
SEVERITY
Elevated
P80 SHIFT
42 → 96 mm
EXPOSED
ML-01 + 2
EVIDENCE
5 linked
HUMAN REVIEW · awaiting engineer sign-off
THIS IS ONE EVENT

Reliat has 3,412 more
in the archive.

Every incident, reconstructed and traced. Explore the history of a line and see what pattern the next event is already following.