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Redefine Reliability

Transform your process and maintenance data into actionable reliability insights. With our online platform and team of engineering consultants, Predict enables Reliability Teams with the data to avoid failures and optimise maintenance scheduling.

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Photo Courtesy: Colin Murty | The Australian

Increase
Safety

Maximise
Productivity

Optimise
Maintenance

Improve
Sustainability

Using Existing Data

A Smarter Way to Maintain

Moving towards a predictive maintenance strategy

Our digital platform, KASEM®, enables maintenance and reliablity teams to make data-driven decisions to eliminate failures, optimise maintenance scheduling, increase the utilisation of parts, evaluate overconsumptions and perform data driven root cause anaylsis.

ABOUT US

Benefit from Predictive Maintenance Across Any Asset

Looking to get more out
of your maintenance
budget?

CONTACT US

SLURRY PUMP CASE STUDY:
REMOVING 30% OF SLURRY
PUMP INSPECTIONS

Benefit from Predictive Maintenance Across Any Asset
SLURRY PUMP INTERNAL HEALTH CALCULATED BY PREDICT
Time-based schedules require unnecessary inspections because the condition of internal parts is unknown.

Remove unnecessary inspections and extend the life of parts with predict.

Throatbush At
84% Health
Throatbush At
91% Health
CALCULATE HEALTH, REMOVE INSPECTIONS

Predict partnered with an Australia mining company in 2021 to optimise their existing maintenance strategies with the help of the health data provided by Predict.

In the first step, Predict analysed the slurry pump system to design an indicator using existing process data to measure the health of the pump. The accuracy of this data was confirmed through two periods where the health measured reflected a relative amount of wear on internal components (throatbush wear pictured).

Upon analysis, as much as 30% of the existing scheduled maintenance was performed without any replacement of parts and therefore could now be removed (points in gold).

EXTEND THE LIFE OF PARTS

This health data allowed us to track the remaining useful life of internal components to issue health-based maintenance rather than a time-based schedule.

Extending the time between rebuilds for a single slurry pump by as little as 30 days results in a cost saving of 16% - over $20,000 per year per pump.

HOT GAS GENERATOR CASE STUDY:
DETECTION OF SENSOR DRIFT
2 MONTHS IN ADVANCE

Benefit from Predictive Maintenance Across Any Asset
PREDICT HOT GAS GENERATOR PERFORMANCE INDICATOR
FAST RESULTS

Predict provided this critical alert to the team on-site within two months of receiving a purchase order.

DETECT CRITICAL FAILURES EARLY

Predict began working with a global mining company in 2019 to reduce maintenance costs and failures across a critical Nickel processing workshop. After a thorough engineering study, Predict designed indicators to closely monitor signifi cant changes across the process including the regulation of the hot gas generator.

This indicator generated an alert that was provided to the reliability team in November 2019 through Predict’s cloud-based platform KASEM® that the regulation system was not performing correctly. The team watched the indicator closely as they investigated the issue, ultimately fi nding a drifting temperature sensor to be the root cause.

Replacement of this sensor was able to be scheduled for an upcoming shutdown, avoiding any impact to production. Upon analysis, Predict’s alert of this sensor drift was provided 1.5 months before any local low alarms and 3.5 months before the high alarm with an interlock.

ENSURING PROCESS SAFETY

Regularly operating at 1,100°C, the hot gas generator at the peak of this drift was up to 1,300°C, posing a threat to the internal refractories, downstream equipment and the safety of operators..

BUCKET ELEVATOR CASE STUDY:
DETECTION OF MATERIAL
BUILDUP TO PLAN ACTIONS

Benefit from Predictive Maintenance Across Any Asset
PREDICT BUCKET ELEVATOR IMBALANCE INDICATOR
Using limited existing process data to implement reliable condition-based maintenance.
SPECIFIC INDICATORS, SPECIFIC ACTIONS

Predict began working with a global mining company in 2019 to reduce maintenance costs and failures across a critical Nickel processing workshop.

Prior to engaging with Predict the site experienced two instances where buckets were
torn from the chain due to corrosion. Predict developed an indicator using existing process data to detect the build up of wet material that promotes corrosion.

Predict’s cloud-based platform KASEM® is used by teams on-site to reliability alert when cleaning of the bucket elevator is required.

Since implementing a condition-based strategy the site has experienced zero failures of the bucket elevator.

CONVEYOR CASE STUDY:
EARLY DETECTION OF POOR
CALIBRATION

Benefit from Predictive Maintenance Across Any Asset
PREDICT CONVEYOR PERFORMANCE INDICATOR
“This was a good pick up by you and your team. The weight of this conveyor is one of the main inputs we use to mix the fi nal product…”
– Asset Specialist
Data to continuously analyse the impact of maintenance actions on the process.
AVOIDING IMPACTS TO PRODUCTION

Predict partnered with an Australia mining company in 2021 to optimise their existing
maintenance strategies with the help of the health data provided by Predict.

Predict designed an indicator to monitor the performance of a key conveyor using existing process data. Once deployed, an alert was generated by Predict’s cloud-based platform KASEM® indicating a signifi cant change in the performance of the conveyor.

Upon investigation, asset specialists on site discovered 100t/h less material was being
delivered due to poor calibration of the encoder that provides the speed needed by the weightometer and work was scheduled.

Once calibration was carried out on the weightometer the conveyor performance
indicator returned to nominal.

O2 SENSOR CASE STUDY:
EARLY DETECTION OF
SENSOR FAILURE

Benefit from Predictive Maintenance Across Any Asset
PREDICT O2 ANALYSER HEALTH INDICATOR
ENSURING PROCESS SAFETY

Predict’s alert ensured that the drift in this critical process measurement
was discovered before any potential impact to the safety of the process.

AVOIDING IMPACTS TO PRODUCTION

Predict began working with a global mining company in 2019 to reduce maintenance costs and failures across a critical Nickel processing workshop.

Predict designed indicators to monitor the health of critical instruments throughout the process using existing data including CO2 and O2.

An alert was provided to the team through Predicts cloud-based platform KASEM® picking up a drift of an O2 sensor. Upon investigation, the team on site discovered a faulty connection to the sensor and was able to switch to an alternate sensor for this measurement to avoid any disruption in production.

In the following days maintenance was performed to replace the probe and switch back to the correct measurement of the process.

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