Ok Tedi Mining Limited
Provisions of Asset Management System
- Papua New Guinea
- Aspen Mtell®
- Mining
Background
The Ok Tedi Mine, 100% owned by Ok Tedi Mining Limited (OTML) is an open-pit copper and gold mine located near the headwaters of the Ok Tedi River in Papua New Guinea’s Western Province.
Mipac has been working with OTML for many years, including on projects such as the Automation Roadmap project, Power Improvement Project and Processing Asset Renewal Project. For this reason, the team has a deep understanding of the Ok Tedi site and its challenges, as well as a strong relationship with the local operations team.
Project Scope
Following some major breakdowns on site, and in line with other major asset upgrades (for example those covered in the Power Improvement and Processing Asset Renewal projects that Mipac is currently working on at Ok Tedi), OTML contacted Mipac to help source an asset management system which would tell them in advance (before a breakdown) which equipment or asset required maintenance and when, as well as giving them a forecast into the results that could be achieved if assets were operating properly.
The main goal was to improve production, reduce the need for maintenance and increase asset reliability.
OTML was particularly interested in futuristic solutions which contained a level of Artificial Intelligence capability to help them achieve these goals.
Specifically, Mipac was engaged to complete an evaluation of potential Asset Management Systems for Ok Tedi and source the best possible solution for deployment on the site.
This evaluation, completed on 9 November 2023, found that the AspenTech Mtell® system to be the best fit for OTML’s requirements.
It was agreed that Mipac, with AspenTech support, would perform an online deployment of Aspen Mtell® software using sensor time-series and maintenance historical data provided by OTML.
The deployment would be limited to ten (10) OTML assets to be agreed upon by both parties, and may include compressors, pumps, turbines, heat exchangers or other rotating or fixed assets as identified within OTML’s reliability program. The first 5 assets are be delivered by AspenTech with Mipac support, and the second 5 assets will be delivered by Mipac.
This project is expected to take a year, with the timeline as follows:
- Project kick off
- Project installation/deployment – Four months (17 weeks).
- Monitoring and Support – Nine months (37 weeks)
The AspenTech Mtell® system
Aspen Mtell® software is a powerful equipment analytics solution that accurately predicts an anomaly in monitored equipment and its related process, indicating precisely when and how an event is likely to occur. This solution leverages machine learning to identify and alert on early patterns of degradation which lead to reduction in useful life. The resulting output provides insights that can assist in the containment of risk, supporting a strategic transformation program, which can drive net results with an increase in production output and a reduction in expenses relating to equipment ownership, maintenance costs and overall energy consumption.
The Mtell® software executes very precise pattern recognition of changes in streaming signals produced from sensors on and around the equipment being monitored. This permits detection of extremely early onset of equipment degradation through multi-variate differences across all the streaming signals and through temporal distinctions: tiny changes in the streaming signals, offset by time.
Visit the AspenTech website for more information.
Unique and Innovative
This is the first time Mipac has recommended AspenTech’s solution to a client.
What's next?
Whilst the implementation of Mtell® will take up to 12 months, OTML has also agreed for Mipac to provide – beyond the implementation phase, 50 remote support hours per month for any remote engineering works (creating and re-training agents, tracking, reviewing and escalating alerts, acknowledging and closing alerts). This includes:
- Daily review, classification, and escalation of alerts
- Weekly alert reviews
- Monthly online reports summarising business KPI review and support hours consumption
- Brisbane office hours dedicated phone access for Mtell® application services support
In addition, there may be some eLearning provided to ensure knowledge transfer.
Want to know more about how Aspen Mtell® can optimise your complex mineral processing operation?
Aspen Mtell goes beyond traditional monitoring by becoming a proactive guardian of your assets. It deploys intelligent “agents” that continuously monitor and analyse sensor data from your critical equipment. These agents leverage various methodologies to predict potential failures before they occur. Read more about AspenTech Mtell.
