Dave Hunter Group Leader - Metallurgical Accounts, QNI Pty Ltd Using PI for BSC Reporting at QNI
OSI PI Users Conference 2004, San Francisco, April 2004
Page 2
Outline
• Yabulu Refinery Overview
• Business Systems Architecture
• Yabulu Refinery Performance Measures
• Other Business Benefits
• Questions
OSI PI Users Conference 2004, San Francisco, April 2004
Page 3
Overview
P H I L I P P I N E S
I N D O N E S I A
A U S T R A L I A
N E W
C A L E D O N I A
Hinatuan
Gee Gebe
Yabulu
Greenvale
Brisbane
Karembe
Teoudie
Baie Ugue
Kouaoua
Boakaine
Nakety Noumea
Rio Tuba Taganito • BHPBilliton’s nickel business
• Operations in Australia and Colombia
• World’s 5th largest nickel and cobalt producer
• 3.5 M tpa of imported ore produces 32 000T Ni and 2000T Co
• Employs 700 people
Yabulu Ore Sources
OSI PI Users Conference 2004, San Francisco, April 2004
Page 4
Yabulu Refinery Overview
Water recycling
facility
3TP Nickel
Compacts
OSI PI Users Conference 2004, San Francisco, April 2004
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Yabulu Refinery Overview cont...
6 Control Rooms
Mixture of Different Control Systems
PI installed November 2000
•Administered by IT Department
•Champions in each Business Unit
Refinery BSC Reporting Implemented FY03
OSI PI Users Conference 2004, San Francisco, April 2004
Page 6
Business Systems Functional Hierarchy
PIMS
Incident Mgt
First Priority
LMS
Traccess
Sales & Marketing
MSAP
Accounting, Maintenance, HR, Supply
QSAP
Ore Ship & Train
Scheduling
G2
DCS System6 & PLC’s
Expert System
Connoisseur
Data Historian
(OSI PI)
LIMS
CCLAS
Reconciliation
S-fine
Risk Mgt
RMS2000
Asset Mgt
Activa
Plant Mass
Balancing
Metsim
KPI & Advanced Calcs
PI-ACE
Forecasting
MS Excel
Alarms
PI-SQC
Production
MS-SQL
MSDS’s
ChemAlert
OSI PI Users Conference 2004, San Francisco, April 2004
Page 7
Automatic PIMS Interfaces
PIMS
SAP
R/Link-PM
Excel
PI-SDK
MSDS’s
HTTP
Weather Station
PI-RDBMS
LIMS PI-RDBMS
Σ
Statistica
PI-ODBC
Intranet PI-ODBC
Crystal
Reports
PI-ODBC
OSI PI Users Conference 2004, San Francisco, April 2004
Page 10
Production & Efficiency - Nickel Plant
Critical calciner KPI’s monitored in real-time
OSI PI Users Conference 2004, San Francisco, April 2004
Page 12
Production & Efficiency - Roasters
Monthly Average Hearth Hit Rate
48
50
52
54
56
58
60
Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Jan-04 Feb-04
%
Actual
Target
% of time temperature was within ±10°C of SP during the last 6 hours
OSI PI Users Conference 2004, San Francisco, April 2004
Page 13
Production & Efficiency - Grinding
Hours Both Ball Mills Running
0
20
40
60
80
100
120
140
160
A B C D
Shift
ho
urs
Peak Power
Off-Peak Power
Compare KPI’s between Shifts
Peak power is purchased at higher rate than off-peak
OSI PI Users Conference 2004, San Francisco, April 2004
Page 14
Production & Efficiency - Dryers
Operator log for entering reasons for downtime events
Uses PI Alarm tags as triggers, and events saved in SQL table
/SQL="select COUNT(*),0 from dtmPrimary where Equipment1 = '320' AND
StartTime > ?;" P1='PE.680.TS.Today'/VL
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Dryers
•Downtime summary report, using Crystal Reports
•Adhoc reports executed from Excel / MS Query for maintenance reporting
OSI PI Users Conference 2004, San Francisco, April 2004
Page 16
Production & Efficiency - Dryers
Equipment tree and reason sets stored in PI-MDB
OSI PI Users Conference 2004, San Francisco, April 2004
Page 17
Production & Efficiency - Dryers
Downtime
Service
RTDB
-Trigger Tags
MDB
-Equipment Tree
-Reason Sets
-DB Connections
SQL DB
Configuration
Tool (OCX Control)
Downtime Client
(OCX control)
Developer’s PC
SQL Server
PI Server
•Downtime monitor data flows
OSI PI Users Conference 2004, San Francisco, April 2004
Page 18
Production & Efficiency - Metallurgical Accounting
Sigmafine used to perform monthly reconciliations for nickel and cobalt
Allows flowsheet mass balance to identify unmeasured losses
Input data can be read from PI tags or csv file
Has allowed monthly Metallurgical Accounting reports to be completed in 1 working day
Report on intrinsic data quality i.e. meter & weigher accuracy
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Metallurgical Accounting
Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Metallurgical Accounting
Report on measured and reconciled mass through each meter
Report on data quality and quality of mass balance
OSI PI Users Conference 2004, San Francisco, April 2004
Page 21
Profitability & Growth - Project ROI
Calculate payback from improvement projects by writing current nickel & cobalt prices to PI tags, and using in Data Sets
OSI PI Users Conference 2004, San Francisco, April 2004
Page 22
Environment & Community - Stack Discharges
Using SQC Chart Histogram for MTD KPI’s
Double clicking chart title bar display statistics
OSI PI Users Conference 2004, San Francisco, April 2004
Page 23
Health & Safety - CRO Logs
•Operator names recorded in PI string tags
•Safety & training stats and text saved in SQL Server
•PI Trend showing tank levels for duration of shift
OSI PI Users Conference 2004, San Francisco, April 2004
Page 24
PI-ACE used to write monthly measures to BSC database
BSC database connection string stored as property in MDB
BSC Measure tags saved as aliases in MDB
MeasureID stored in “UserInt1” tag attribute
Other Business Benefits - Updating BSC Using PI-ACE
OSI PI Users Conference 2004, San Francisco, April 2004
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Other Business Benefits - Updating BSC Using PI-ACE
OSI PI Users Conference 2004, San Francisco, April 2004
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Other Business Benefits - Process Capability for ISO9001
For a process that is normally distributed it is known that 99.73% of all values are within the ± 3 sd around the mean
Review data which falls outside this range to determine the cause. Exclude this data if the process was unstable
Calculate process capability based on a 95% confidence level around the process mean
This is what we know the process is currently capable of achieving.
Configure PI-RTSQC Alarms for when process goes outside these control limits, and raise incident in FirstPriority
OSI PI Users Conference 2004, San Francisco, April 2004
Page 27
QNI PIMS Scorecard
• How up to date is the production information published on
our intranet ? J
K
L
K
J
• At what level of detail do we compare performance ?
• What interval is performance data tracked ?
• Who has access to this data ?
• How do we collect downtime ?