Detection of Sensor Drift 2 Months in Advance
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.
PREDICT HOT GAS GENERATOR PERFORMANCE INDICATOR
Predict provided this critical alert to the team on-site within two months of receiving a purchase order.
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