dave hunter group leader - metallurgical accounts, qni pty ltd using pi for bsc reporting at qni

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

Outline

• Yabulu Refinery Overview

• Business Systems Architecture

• Yabulu Refinery Performance Measures

• Other Business Benefits

• Questions


OverviewP 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 WC A L E D O N I A

Hinatuan

GeeGebe

Yabulu

Greenvale

Brisbane

Karembe

Teoudie

Baie UgueKouaoua

BoakaineNakety

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


Yabulu Refinery Overview

Water recycling

facility

3TPNickel

Compacts


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


Business Systems Functional Hierarchy

PIMS

Incident MgtFirst Priority

LMSTraccess

Sales & MarketingMSAP

Accounting, Maintenance, HR, SupplyQSAP

Ore Ship & TrainScheduling

G2

DCSSystem6 & PLC’s

Expert SystemConnoisseur

Expert SystemConnoisseur

Data Historian(OSI PI)

LIMSCCLAS

Reconciliationfine

Risk MgtRMS2000

Asset MgtActiva

Plant MassBalancing

Metsim

KPI & Advanced Calcs

PI-ACEKPI & Advanced Calcs

PI-ACE

ForecastingMS Excel

AlarmsPI-SQCAlarmsPI-SQC

ProductionMS-SQL

MSDS’sChemAlert


Automatic PIMS Interfaces

PIMS

SAP

R/Link-PM

Excel

Excel

PI-SDK

MSDS’s

HTTP

WeatherStation

PI-RDBMS

LIMS PI-RDBMS

Σ

Statistica

PI-ODBC

IntranetIntranet PI-ODBC

Crystal

Reports

Crystal

Reports

PI-ODBC


Yabulu Balanced Scorecard


Example Business Unit Scorecard


Production & Efficiency - Nickel PlantCritical calciner KPI’s monitored in real-time


Production & Efficiency - Roasters


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

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


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

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 ShiftsPeak power is purchased at higher rate than off-peak


Production & Efficiency - DryersOperator log for entering reasons for downtime eventsUses 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

/SQL="select COUNT(*),0 from dtmPrimary where Equipment1 = '320' AND StartTime > ?;" P1='PE.680.TS.Today'/VL


Production & Efficiency - Dryers

•Downtime summary report, using Crystal Reports

•Adhoc reports executed from Excel / MS Query for maintenance reporting

•Downtime summary report, using Crystal Reports

•Adhoc reports executed from Excel / MS Query for maintenance reporting



Equipment tree and reason sets stored in PI-MDBEquipment tree and reason sets stored in PI-MDB



DowntimeService

RTDB

-Trigger Tags

MDB

-Equipment Tree

-Reason Sets

-DB Connections

SQL DB

ConfigurationTool (OCX Control)

Downtime Client(OCX control)

Developer’s PC

SQL Server

PI Server

•Downtime monitor data flows


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



Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations



Report on measured and reconciled mass through each meter

Report on data quality and quality of mass balance


Profitability & Growth - Project ROI

Calculate payback from improvement projects by writing current nickel & cobalt prices to PI tags, and using in Data Sets


Environment & Community - Stack Discharges

Using SQC Chart Histogram for MTD KPI’s

Double clicking chart title bar display statistics


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


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


Other Business Benefits - Updating BSC Using PI-ACE


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


QNI PIMS Scorecard

• How up to date is the production information published on our intranet ?

• 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 ?


Questions ?

dave hunter group leader - metallurgical accounts, qni pty ltd using pi for bsc reporting at qni

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