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.

STATISTICAL
P80 particle size
96mm+128%
baseline 42 mm
CONTROL RULE
Points beyond USL
11consecutive
Western Electric rule 1
MASS BALANCE
Oversize to mill feed
+6.1t/h
vs. recirculation baseline
PHYSICS
Mill power draw
+140kW
correlated, 1m47s lag
CONTROL
Belt speed
2.4m/sflat
rules out throughput artifact
PHASE 01 · ROOT CAUSE

Ranked hypotheses, with what
supports and what's still missing.

1
Crusher CSS drift
Closed-side setting opened, letting oversize through the crush zone.
CONFIDENCE 0.72
SUPPORTING
Motor amps ↓ 8%
P80 rise matches gap
Localized to deck 2
CONTRADICTING
No liner-wear alarm
MISSING
Last CSS calibration log
2
Screen panel failure
A torn deck panel passing oversize straight to product.
CONFIDENCE 0.19
SUPPORTING
Bypass on one deck
CONTRADICTING
Even size across width
No inrush on screen motor
MISSING
Deck camera frame
3
Feed surge / segregation
A momentary feed spike overwhelming the crush zone.
CONFIDENCE 0.09
SUPPORTING
Feeder speed spike 14:22
CONTRADICTING
Size sustained past surge
No level drop in bin
MISSING
Feed hopper level trace
PHASE 02 · PROPAGATION

The same event,
traced through the plant.

PROPAGATION TIMING
Crushert0
Conveyor CV-02+38 s
Screen SC-01+52 s
Mill ML-01+1m 47s
EXPOSED ASSETS
ML-01 liners ML-01 cyclone Load-out spec
PLAUSIBLE EFFECTS
Mill overload trip risk within 4 min · accelerated liner wear · downstream spec breach at load-out if uncorrected.
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.