AspenTech’s Robert Macaulay presented Reduce Plant Maintenance Costs and Increase Reliability with Aspen Mtell Software for Asset Performance at the 2024 Ovation Users Group Conference. Here is his presentation abstract.
AspenTech Mtell software utilizes best-in-class advanced pattern recognition technology to detect failures and anomalies on mechanical assets, helping reduce maintenance costs and plant downtime associated with equipment out of service. Extending beyond simply alerting to issues, Mtell also provides prescriptive maintenance actions based on Emerson’s extensive database of equipment specific fault diagnostics, pinpointing root cause issues and corrective actions to address them. Powered by AI and machine learning designed just for maintenance and reliability, learn how AspenTech’s Mtell software detects the earliest signs of equipment degradation to transform organizations and improve asset availability, equipment uptime, throughput, and safety.
Robert opened by noting that, per McKinsey, the transition to a net-zero economy will be metal-intensive. As we move towards cleaner technologies, we will need vast quantities of raw materials for the energy transition. Metals and mining are a long-lead-time, highly capital-intensive sector, so price increases and bottlenecks will be unavoidable as demand outstrips supply.
Also, the workforce’s characteristics are evolving, adding new expectations and introducing knowledge gaps that require years to ramp up. Companies need compelling ways to attract the latest generation of technical workers and empower them to be effective rapidly.
There are also overwhelming amounts of data; various digitalization tools are available, but making sense of it to understand business impact is becoming difficult.
Well-maintained and optimally performing equipment are the cornerstones of a successful business operation. It’s important to note that many business risks originate at the equipment level. Asset performance has a profound impact on several critical factors, including:
- Safety of personnel
- Product quality
- Customer satisfaction
- Revenue and profitability
- Energy or resource consumption
Aspen Mtell allows maintenance & reliability engineers to monitor equipment health and performance using various technologies. It monitors assets in the context of their usage to provide the earliest possible warning failure weeks or months in advance.
Mtell looks at historical data to understand an asset’s ‘normal behavior’ and maintenance data to find key failure events. It is prescriptive because it issues actionable advice, allowing plant personnel to adjust process conditions and maintenance schedules and manage inventory and delivery commitments. This allows for enhanced collaboration between different organizations in your facilities.
Mtell can also integrate with other AT solutions, such as Aspen Plant Scheduler and Aspen Fidelis, to identify the best time to schedule maintenance. This method considers the costs of multiple downtime options while minimizing the impact on production and supply chain.
Sensors measuring temperatures, speeds, vibrations, etc., are arranged in groups to detect precise degradation and failure conditions. Depending on the maintenance strategy for a piece of equipment, you can deploy various agents for optimal results. These agents monitor the plant or process 24/7. Agents work in real-time by learning, adapting, and retaining this knowledge forever. Agents can also be transferred across similar assets.
The information derived from these agents enables dashboards and key performance indicators (KPIs) which enable:
- Quicker Decisions: Instant, at-a-glance data visualization for swift, informed actions
- Better Operational Efficiency: Tailored operations tracking for streamlined processes and productivity boost
- Longer Asset Life: Advanced tools for early issue detection, ensuring extended asset lifespan.
- Faster Strategic Alignment: Maintenance plans synced with business goals for overall performance enhancement
- User-defined layouts for a fit-for-purpose monitoring experience
The Alert Manager helps visualize and prioritize active alerts, document detailed information on an impending failure, or access embedded recommendations for known failures to quickly resolve equipment health issues. It provides a structured workflow and enables cross-functional collaboration for consistent and effective response.
Robert shared how successful projects include executive leadership support, close partnering with the customer and project team, establishing clear business objectives, customer journey mapping and alignment, and KPI monitoring and tracking.
A Latin American midstream oil and gas company transports, stores, and ships crude oil. As the country’s production fell, this company was forced to operate its facilities at reduced capacity (just 30- 50% of maximum capacity) while ensuring the reliability of spare assets. It increased engine overhaul from 16,000 hours to 19,200 hours — a 20% improvement in uptime that resulted in savings of almost $500,000 per year in maintenance costs, a 25% reduction.
For one global Life Sciences company, millions of dollars in potential savings were achieved by applying Mtell to 30 sites across 18 countries, multiplying the value gained. This new predictive and prescriptive maintenance schedule delivered a 50% reduction in associated lifecycle costs, a 60% reduction in capital expenditures (CAPEX), and a dramatic improvement in overall operator confidence.
In summary, the Aspen Mtell solution helps increase production throughput by improving equipment availability and reliability, reduce operating expenses by minimizing maintenance costs and spare parts inventory, and reduce safety and environmental incidents by transforming emergency work into planned work.
Visit the Aspen Mtell section on Aspentech.com for more information on how you can drive operational performance improvements.
