KNS Koniambo Nickel Plant Maintenance & Engineering Support

Client

Koniambo Nickel SAS

Location

Kone, New Caledonia

Timeframe

2021

Scope

In 2020, KNS initiated a transformation project to push the production and reliability of the facility closer toward nameplate capacity. QGE was initially engaged at this time to assist with an instrument re-commissioning project on Line 2. Evidence pointed to a lot of issues with the original commissioning of the facility, poorly executed or incomplete. Three engineers and one instrument technician were part of the original team involved in the Line 2 recommissioning project.

During this work, additional project scopes were identified, and this resulted in QGE being engaged for two additional projects:

By the utilities team in a project to upgrade the coal plant control system.
The control system stability project that formed a pillar of the KNS transformation initiative.

Background

The KNS Koniambo Nickel mine consists of a mine on the mountaintops near to the town of Kone, and a processing plant 15km away, on the coastline. The processing plant comprises a power station, coal plant, and two crushing, drying and smelting lines. The site was initially commissioned and commenced production in 2013, however since this time it has never reached nameplate production, and usually operates below half of the stated capacity of 60,000tpa. QGE were engaged to assist with bringing the site production up to nameplate rating.

All this work was undertaken within the context of the COVID-19 pandemic and restrictions on international travel, thus all staff involved in the project were required to commit to 3-month+ stints away from home, including quarantine.

Outcomes

Using a recognized, standardised commissioning approach, QGE were able to work with KNS employees and local contractors to achieve the goal of recommissioning approximately 1,300 instruments during the line 2 shutdown window. In addition to completing the required scope within timeframe provided, the exercise also provided on ongoing opportunity to work with the KNS engineers and technicians to provide skills uplift, and guidance in a measured approach to achieving the task.

A number of latent commissioning issues were discovered and rectified, and several new instrument scopes identified for future works, and fed into the control system stability work.

The ongoing presence of QGE I&E technicians and engineers in the maintenance team have provided continuous support for the site’s operation, a skills uplift to the KNS team, and addressed some key reliability problems.

Why Choose Us

WE ARE THE EXPERTS IN THE FIELD

QGE are recognised leaders in hazardous areas and in grid connected solar PV, which is only possible because of our rock-solid foundation in electrical and controls engineering. We have the knowledge and experience to provide a cost-effective solution, whatever the problem.

WE ARE CONSTANTLY INNOVATING

Our cloud software, controls and telemetry solutions, and grid export control panels are all products of our ongoing investments in new technology and engineering processes, and we continue to push the boundaries with involvement in blockchain and peer-to-peer energy trading.

WE ARE EASY TO WORK WITH

At QGE we genuinely enjoy what we do, which means we’re always willing to go the extra mile for our customers to deliver the right solution. We have great client relationships because people like working with us.

Testimonials

Over several years, QGE have provided control systems design and on site support for upgrades and expansion projects. We’ve been very satisfied with the quality of their solutions and the high level of support they have provided our remote mine site.

Jude Barnes

Sepon Mine Site - MMG

QGE have worked with us for several years on hazardous area issues and have classified a number of our facilities, including new-technology processes, where we’ve been very satisfied with the pragmatic approach they’ve taken and the outcomes for our business.

Ferdi van Staden

Coogee Chemicals

The QGE team understood the project’s constraints and requirements, and were able to deliver a commercial solution that has allowed Agrimin to achieve a higher renewables penetration and lower energy cost than it had expected.

Rhys Bradley – Chief Commercial Officer

Agrimin