Académique Documents
Professionnel Documents
Culture Documents
2011
Developing an
Operation, Maintenance and
Surveillance Manual
for Tailings and Water Management Facilities
ISBN 0-921108-25-7
www.mining.ca
Foreword
It is with pleasure that I present, on behalf of the members of The Mining Association
of Canada (MAC), Developing an Operation, Maintenance and Surveillance Manual for
Tailings and Water Management Facilities. This guide is the result of many months of
deliberation by a 22-member team of mining industry specialists and practitioners. We
are extremely grateful to the team members and their corporate sponsors for their gener-
osity, skill and dedication in responding to this difficult challenge.
In keeping with MACs commitment to continual improvement and sustainable devel-
opment, the guide reflects the principles embodied in the associations Environmental
Policy and Towards Sustainable Mining draft Guiding Principles, and complements
its forerunner, A Guide to the Management of Tailings Facilities. Like the management
guide, it encourages mining companies to practise safe and environmentally responsible
management of tailings and water management facilities; however, this guide does so by
focusing on the need for a site-specific operation, maintenance and surveillance (OMS)
manual as an integral component of an overall tailings management system. Such a
document can help companies comply with government regulation and corporate policy,
demonstrate voluntary self-regulation and due diligence, practise continual improve-
ment, and protect employees, the environment and the public.
The guide reflects principles and practices from a variety of sources. It addresses site-
specific issues in a practical manner, reflecting the priorities of owners, managers and
practitioners whose job it is to continually improve the performance of the mining indus-
try in Canada and abroad.
Pierre Gratton
President & CEO
The Mining Association of Canada
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities i
Preface
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities iii
Table of Contents
1. Introduction.............................................................................................................................. 1-1
2. Preparing an OMS Manual.................................................................................................... 2-1
OMS Manual Development Team................................................................................................ 2-1
Objective of an OMS Manual....................................................................................................... 2-1
Resources and Scheduling............................................................................................................ 2-2
OMS Manual Control and Update................................................................................................ 2-2
3. Roles and Responsibilities................................................................................................... 3-1
Organization, Structure, Individual Responsibilities................................................................. 3-1
Competency and Training............................................................................................................. 3-2
Managing Change.......................................................................................................................... 3-2
4. Facility Description................................................................................................................ 4-1
Facility Overview.......................................................................................................................... 4-1
Site Conditions.............................................................................................................................. 4-2
Facility Components..................................................................................................................... 4-3
Regulatory Requirements.............................................................................................................. 4-4
Basis of Design and Design Criteria............................................................................................. 4-5
Construction History..................................................................................................................... 4-7
Document Control......................................................................................................................... 4-8
5. Operation...................................................................................................................................... 5-1
Objective........................................................................................................................................ 5-1
Tailings Transport and Deposition............................................................................................... 5-3
Dam and Basin Raising................................................................................................................. 5-5
Water Management........................................................................................................................ 5-6
Environmental Protection............................................................................................................. 5-7
Safety and Security....................................................................................................................... 5-8
Documentation.............................................................................................................................. 5-8
Reporting....................................................................................................................................... 5-8
6. Maintenance............................................................................................................................... 6-1
Objective........................................................................................................................................ 6-1
Maintenance Parameters............................................................................................................... 6-3
Routine and Predictive Maintenance........................................................................................... 6-3
Event-Driven Maintenance........................................................................................................... 6-3
Documentation.............................................................................................................................. 6-4
Reporting....................................................................................................................................... 6-4
7. Surveillance............................................................................................................................... 7-1
Objective........................................................................................................................................ 7-1
Surveillance Parameters............................................................................................................... 7-3
Surveillance Procedures............................................................................................................... 7-4
8. Emergency Planning and Response................................................................................. 8-1
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities v
Table of Contents
annexe
a1. MAC Towards Sustainable MininG GUIDING PRINICPLES....................................a-1
List of Figures
Figure 1: Elements of the tailings and water management framework...................................... 1-2
Figure 2: Application of an OMS manual through the life cycle of a tailings or
water management facility............................................................................................................ 1-3
Figure 3: Operation flowchart...................................................................................................... 5-2
Figure 4: Maintenance flowchart.................................................................................................. 6-2
Figure 5: Surveillance flowchart.................................................................................................. 7-2
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 1-1
1 Introduction
Site Selection
and Design
Application of
Construction an OMS Manual
Decommissioning
and Closure
Time
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 1-3
Chapter 2 Preparing an OMS Manual 2
The preparation of an OMS manual requires: OMS Manual
Development Team
n setting up a team to develop an OMS manual;
Objective of an OMS
n establishing objectives, a realistic budget and schedule to develop the manual; Manual
n compiling information from many sources, within the company and beyond;
n establishing procedures for implementing, controlling and updating the OMS
manual; and
n assuring that operational, engineering, corporate and regulatory issues are
addressed.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 2-1
2 Preparing an OMS Manual
Objective of an OMS An OMS manual should present information in a clear, logical and user-friendly manner.
Manual Any supporting documentation should be clearly referenced. The reader should be able
Resources and to identify easily what is required and how to access the information needed.
Scheduling
The manual should enable the performance of a facility to be compared to expectations,
OMS Manual Control
design criteria and operating intent, particularly in the event of significant incidents.
and Update
Preparedness
Maintenance
Surveillance
Typical Designated Personnel for OMS
Emergency
Operation
u It is essential for
Mine/mill general manager
the integrity of opera-
Tailings area supervisors tions that the facility
management structure
Tailings engineers and technicians and individual roles,
Environmental engineers and coordinators responsibilities and
required competencies
Personnel responsible for facility inspections of personnel be clearly
Personnel responsible for dam raising defined.
Personnel need to
Tailings area operators and foremen
understand the factors
Water management/treatment area operators and foremen that constitute sound
performance of a tailings
Mill foremen (attending tailings discharge and recycle water requirements) or water management
Tailings backfill plant operators facility, how deviations
from expected perfor-
Site emergency/security personnel mance may indicate
External advisors/consultants developing problems,
and their individual
Mechanical/electrical foremen roles in facility OMS.
A new member of the
Electricians
team should be able to
Mechanics comprehend readily the
facility management,
Heavy equipment operators organization and reporting
Scientists structures, and be able to
contact the appropriate
Administration support management personnel
using the information
External liaison/public affairs personnel
provided.
Legal and regulatory affairs personnel
Engineer(s) of record
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 3-1
3 Roles and Responsibilities
Managing Change
Define procedures for making changes to design or operating plans, such as where condi-
tions encountered in the field differ from design. Ensure that the process of changing
u Tailings and water design includes obtaining authorization of the changes.
management facilities Identify responsibility for reviewing, updating and improving the OMS manual, to
change. Revisions to
design during operations respond to:
should follow a defined n evolution of design through capacity changes, operational efficiencies, closure
review and approval
process, appropriately requirements, performance feedback and life-cycle changes;
involving company n incorporation of as-built records of construction;
management, site
personnel and regulators. n variation of performance from design;
n changes in site management organization, facility description, roles and responsi-
bilities, and operating and reporting procedures;
n suggestions for improvement;
n succession planning/training; and
n regulatory change.
Facility Overview
Provide an overview of the facility, setting the context of its surroundings, related opera-
tions and its history.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 4-1
4 Facility Description
Climate temperature, wind, precipitation, evaporation, seasonal and extreme events, precipitation and runoff,
air quality
Water
u hydrology regional creeks, streams, rivers, ponds and lakes, marine conditions, catchment area, down-
stream areas that may be affected, and water flow, volume, chemistry/quality, and biology
u hydrogeology aquifers, and water flow, volume, direction and chemistry/quality
Land forms topography, including muskeg, peat or talus slopes
Geology and geochemistry surficial deposits and bedrock characteristics (moisture content, gradation, mineral-
ogy, geochemistry, shear strength, compressibility, permeability and index tests), stratigraphy, geomorphology,
mineral and petroleum resources, background elemental content
Natural hazards landslides, avalanches and debris torrents, seismicity, flood potential, frost action, wind, ice
movement, frazil ice
Surrounding land and water tenure and use
Biological ecosystem identification, flora and fauna
Provide location, and essential supporting field and analytical program data related to the
site.
Typical Site Reference Data
Provide a listing of significant equipment and structures that comprise the facility,
including those associated with tailings delivery and tailings or water management.
Tailings/Water Management
Infrastructure
Instrumentation
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 4-3
4 Facility Description
Facility Components Include relevant supporting data and references for components of the facility in a
Regulatory summary table, including appurtenances and instrumentation types.
Requirements
Typical Component Details
Regulatory Requirements
List all regulatory approvals. Describe their purpose, compliance and reporting require-
ments, and respective periods of applicability. Include reference to the personnel
responsible for ensuring compliance, permit tracking procedures, and the locations of all
regulatory documentation.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 4-5
4 Facility Description
Basin capacity, footprint, hydrology, operational life Elevation change and distance from mill
Siting constraints, natural hazards Foundation conditions
Climatic considerations Surficial and bedrock geology
Operating Requirements
Ore reserve, life of mine, annual Slurry water chemistry Regulations
through-put Dam crest width Acid-generating potential
Tailings pulp density in delivery Tailings beach width and slope Pond retention time, pond
pipeline chemistry
Water quality standards for surface
u Closure requirements Tailings production and basin and groundwater Pond seepage control measures,
also influence the oper- filling rates, impoundment raising perimeter surface and groundwater
Water balance, mill reclaim water
ating design of a facility. schedule
rate, treatment plant capacity chemistry requirements
Therefore, the design
basis and criteria for Tailings characteristics, including Catchment area runoff diversion
Water management (including
closure, including decom- gradation, chemistry, mineralogy, requirements
diversion works, outlet structures
missioning and reclama- dry settled density
and freeboard requirements) Decommissioning, closure and
tion, should be included in Tailings deposition procedures
the manual. Closure plans Pond freeboard, settlement and reclamation
cycloning, spigotting, cell construc-
often evolve through the consolidation
operation stage of the tion, end discharge
facility. Changes need to
be tracked in the manual.
Design Criteria
Standards set by engineering practice and/or regulation
Dates of construction
General description of the construction
Engineer of record, construction contractor
Size, scale, complexity and ease (or difficulty) of construction of each stage
Summary of the key elements of the facility that were constructed
Type and source of construction materials
Summary of problems or unique circumstances encountered, including natural (ground conditions, weather, etc.)
or human-made (changes from approved design, construction methods differing from standard, etc.) conditions
List of supporting documentation providing more specific details relating to the construction
u investigations, designs, specifications, as-built records, photographs, etc.
u list of key individuals supervising and documenting the construction
u stage construction linkages to tailings and water management, etc.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 4-7
4 Facility Description
Objective
Define operating standards and procedures in accordance with design criteria, regulatory
requirements, company policies and sound operating practices, encompassing all signifi-
cant aspects of, and activities for, the economical, safe and environmentally responsible
disposal and storage of tailings and management of water.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 5-1
5 Operation
no
Modify
n Design
n Operation
n Maintenance
n Surveillance
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 5-3
5 Operation
n valve openings
Identify requirements and plans for staged dam construction over the life of the facility,
to maintain adequate solids storage capacity and allow adequate polishing of supernatant
during operation, including:
n methods of dam construction spigotting, cell construction, upstream, down-
stream, etc.;
n tailings deposition procedures, taking into consideration dam safety staging
of dam lifts, solid storage capacity, water recycling and water treatment require-
ments; and
n quality control measures to ensure that the construction is completed properly.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 5-5
5 Operation
Minimum freeboard
Stage storage curves
Maximum and minimum operating water levels and beach widths (seasonal considerations, wind, flood and
drought events, and the treatment schedule)
Tables of target pond levels
Water discharge, volume and quality (normal operating conditions and special circumstances)
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 5-7
5 Operation
Typical Safety and Security Parameters Typical Safety and Security Procedures
Documentation
Define information to be collected and recorded as part of the facilitys operation.
Checklists and report forms might be included or referenced.
Reporting
Define operating performance information to be reported.
Specify procedures for reporting of:
n operational conditions requiring maintenance; and
n observations which may identify significant change in conditions at the facility.
Objective
Identify key maintenance parameters and procedures to ensure that the individual
components of a facility are maintained in accordance with performance criteria,
company standards, legislative requirements and sound operating practices. Maintenance
plans should be tailored to unique facility characteristics and site conditions.
n required qualifications and familiarity with Schedule for checking emergency equipment and criti-
the OMS manual cal spare parts list
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 6-1
6 Maintenance
no
Adjust
n Design
n Operation
n Maintenance
n Surveillance
u Predictive mainte-
nance utilizes feedback
Routine and Predictive Maintenance from
Outline routine and predictive maintenance procedures for all identified components of equipment operating
the facility, specifying: history
maintenance effort
n prioritization, based on risks and consequences; (costs)
n material and equipment availability; site conditions
to assist in the identifica-
n maintenance action plans, including repairs and replacement as required; and tion of on-time servicing
n documentation of maintenance undertaken. needs to avoid costly,
lengthy or untimely
breakdowns.
Event-Driven Maintenance
u A key component of
Provide procedures to address conditions or incidents requiring maintenance, which may
maintenance planning
arise from observations from other OMS activities, and result in planned or unplanned is preparedness to
maintenance actions, specifying: respond to breakdowns,
incidents or conditions
n prioritization, based on risks and consequences; requiring maintenance.
n maintenance team call-out procedures; It is important, however,
to distinguish between
n material and equipment availability; requirements for main-
tenance and emergency
n maintenance action plans, including repairs and replacement as required; response; maintenance
n lock-out and safety procedures/concerns; actions do not address
emergency situations,
n return to normal operation; and which should be covered
in the emergency
n documentation of maintenance undertaken.
preparedness plan and/or
emergency response plan.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 6-3
6 Maintenance
Documentation Documentation
Reporting
Define information to be collected and recorded as part of the facilitys maintenance.
Checklists and report forms might be included or referenced.
Reporting
Define maintenance information to be reported.
Specify procedures for:
n reporting operational conditions requiring maintenance; and
n reporting significant observations from maintenance activities, including greater
than expected maintenance requirements and excess event-driven maintenance.
Such reporting may be instrumental in identifying and dealing with changed conditions
at the facility.
Objective
Identify key surveillance parameters and procedures for:
u Surveillance is not a
n monitoring the operation, safety and environmental performance of tailings and substitute for design; it is
water management facilities; a necessary component
of good design practice
n promptly identifying and evaluating deviations from expected behaviour that which, to be effective,
affect operational safety, structural integrity and environmental performance of the must be implemented
facility; and through a designed
program.
n reporting significant observations for response.
Ensure that personnel are aware of the need to report and act on observed departures
from expected behaviour.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 7-1
7 Surveillance
Record
Initial Screen:
actual vs. predicted
behaviour
no no no
Identify and describe potential failure modes for assessment and inclusion in a surveil-
lance program. Define the key parameters of surveillance to support the operation of the
facility, building on the identified modes of failure.
Explanation and illustration of how failure could develop, together with probable triggers, visual and instrumenta-
tion effects
Visual observations
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 7-3
7 Surveillance
Instrument measurement
Surveying
Instrument reading
Material testing
Initial screening of visual inspection observations and field data as collected to determine that operations are
within performance criteria
Periodic follow-up screening of collated observations and data to determine trends as related to performance
criteria
Periodic inspection and review
Documentation
Reporting
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 7-5
7 Surveillance
n vegetation Piezometers
Slope inclinometers
Settlement gauges
Thermistors
u Instrument measure-
Meteorological stations
ment and monitoring
quantifies facility
behaviour in comparison
to performance criteria, Provide a complete listing of all instrumentation, with:
and extends operational
observation to beneath n instrument identification;
the surface, beyond the n location identified on a site plan;
range of visual inspection.
n record of installation, date installed, surveyed position, test hole depth, elevation
of top of hole, diameter, backfill details, instrument type, depth, serial number;
n data collection and validation procedures;
n frequency of monitoring;
n data reduction and interpretation procedures;
n calibration issues; and
n data management and storage.
Specify data collection, instrument reading and monitoring frequencies with regard to
design, operating requirements and site conditions.
Specify criteria for initial screening of instrumentation readings in the field at the time
of collection, and identify the basis for rechecking of anomalous readings (which should
remain on record).
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 7-7
7 Surveillance
Documentation Documentation
Reporting
Establish documentation standards for surveillance, including for recording of:
n observations from routine visual observation (departures from or exceptions to
normal conditions);
n instrumentation monitoring and testing;
n evaluations;
n inspections; and
n reviews.
Provide, where practicable, standard forms and checklists.
Establish a hard copy (paper) and electronic filing system for all inspection reports,
photographic and video records, incident reports, instrumentation readings, instrumen-
tation plots, annual inspections and third-party reviews, so that they can be quickly
u The surveillance
program must include retrieved for review and in the case of an emergency.
clear identification of
trigger points or changes Reporting
for mandatory commu-
Specify procedures for initiating emergency response alerts, reporting operational
nication between those
who monitor performance performance that meets expectations, and reporting conditions requiring adjustment
and those who control the to design, operation, maintenance or surveillance.
means to improve perfor-
mance. The surveillance Specify reporting procedures and schedule for regulatory requirements.
program must be linked to
the emergency response
plan so that action is initi-
ated if the performance
of the facility falls below
design standard.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities 8-1
8 Emergency Planning and Response
Develop and maintain contingency plans as part of EPR plans. Test the plans for effec-
tiveness, review them regularly and update them as appropriate.
Widely distribute contingency and EPR plans to appropriate personnel within the organi-
zation, as well as to potentially affected external stakeholders.
* MAC draws on the 1987 Brundtland Commission definition of Sustainable Development: Development
that meets the needs of the present without compromising the ability of future generations to meet their
own needs.
** We use the term Communities of Interest to include all of the individuals and groups who have or
believe they have an interest in the management of decisions about our operations that may affect
them. This includes: employees, contractors, Aboriginal or indigenous peoples, mining community
members, suppliers, customers, environmental organizations, governments, the financial community,
and shareholders.
Developing an Operation, Maintenance and Surveillance Manual for Tailings and Water Management Facilities A1-1
A1 Towards Sustainable Mining Guiding Principles