RLINK PM

BHP-Billiton Escondida

Presenter: Cedric Luyt

Overview

• Process Overview

• Maintenance Requirements & Design

• Systems Overview

• Systems Integration

• RLINK Implementation

• Project Tips

Map

Process Overview

• Ownership: BHP (57.5%), Rio Tinto (30%),

a Japanese consortium (10%) and the

International Finance Corporation (2.5%).

• Minerals: Copper, Gold, Silver

• Mine, Concentrator, Oxide, Pipeline,

Coloso Port

Process Overview

• Open Pit Copper Mine 3050m Altitude

• Concentrator Cu 776KT pa, 120 000 T/day

• Oxide Plant 140 000 T copper pa.

• Concentrate pumped to port for shipping

• Copper Plate shipped to port

Pit

Leaching

Concentrator

Port Coloso

Concentrator

ColosoLoader

Truck Fleet

Process Overview

Maintenance Requirements

• Objective

– Reduce unnecessary planned maintenance

– Reduce maintenance downtime

• How?

– Usage based Maintenance rather than Time Based

– Automatic maintenance notification generation based

on Equipment Status

Maintenance Requirements

• Benefits of Integrated Usage Based

Maintenance

• Reduce effort of manual logging.

• Improve accuracy of information for maintenance

planning

• Reduce maintenance costs

• Improve reliability

• Improve production

Maintenance Requirements

• Benefits of Automatic maintenance

notification generation

• Reduce turn around time

• Improve equipment availability

• Improve production throughput

• Relate maintenance downtime event information

with maintenance notification and work order

process cycle

Design

• Methodology

– Find an appropriate the source of Equipment Usage and

Status in the Mine and Plant

– Transfer information to the Plant Maintenance System

– Incorporate the Usage Parameters into the Plant

Maintenance planning process

– Use the Status Parameters to proactively drive the

Maintenance Notification process

– Continuously improve and tune the system as

experience is gained

Concentrator

HistorianMine Control

Production SystemMine System

ERP II

Control System

Vehicle

System

Laboratory

Mine Planning

Concentrator, Oxide, Coloso

PI

Servers

WENCO

Server

SIGPLAN

Server

SPM

Server

SAP

Servers

MIMS

Servers

Bailey

Servers

Bailey

Servers

Bailey

ServersVIMS STATEX

LAB

Server

VULCAN

Servers

Systems Overview

GSAP

PI PB Concentrator

Cola Ro

0.5

0

1

CANALETA

20

30

40

0

60

0

150

3000

7000

0

40

A

45

-0

A44

A47

Cajón Reruteo

50

0

90

Flotación Rougher

Cajón de Reruteo

Cajón 12 Vías

0

80

0

50

8

40

0

50

0

50

0

50

0

50

0

50

Alimentación Rougher

Ley Alimentacion

2

1

3

15

40

320.05

320.05320.05

%SolFeCu

Linea 1

Linea 2

Linea 3

Linea 4

Linea 5

Linea 6

Linea 7

Linea 8

Tonelajes

2000

4000

0

80001162

3599698 Sag 2

Sag 1

Sag 3

5507 Total

1.51

36.711.63 Fe

Cu

%Sol

HighAlarm

5

4

6

4

6

0

4

0

4

0

4

0.88 Rec Rou

47 Canaleta

Ph Rougher

10

9

12

9

12

9

12

9

12

9

12

0

12

9

120.00 Ph Rougher

A0 A122 A130

PC8

G2-EB

PC1

PC2

PC3

PC4

PC5

PC6

PC7

10.40

10.35

10.39

10.50

PI PB Grinding Line

0

90

7

10273

0.4010.26

0

1200

12

10

9

1416

11 1

A% %

72 A

171 A

-0 A

216 A11

m3h

kW

3489 Tph

8 7

9 10

1112

% +100

58psi psi

25 TphPebbles Retornados

Alimentación

LINEA 3 DE MOLIENDA 3/5/2002 8:15:46 AM intermedia

1448 m3h

1003 m3h

770 m3h

78 %Sol

1201m3h

23 m3h

Experto Sag 3 Lub. Sag 3 PSI´s

0 A

1317378

A%

8036 kW845 psi

106ruido

0 ruido91 Veloc.

814 psi

33

% +100

64% Finos Correa

CASCADA

EXPERT_ON EXPERT_ON

Sag 1 Sag 2 Retorno

7 8 9 10

Pebbles

Alimentadores 7 8 9 10

30

100

84

35

60

45

0

90

5688

Cajón Sag 3

Cajón Bolas 5

Cajón Bolas 6Cajón Bolas 7

% +100 23

17

12

0-0.04 psi

%

-2 m3h

4928 m3h

52565.90

53

0 m3h 6712 m3h

776 PSI 780 PSI

317 m3h

85 m3h

7

%Sol %Sol

1500

A%

100 %

Auto

AutoAuto

70695

kW

51 m3h

Manual

Auto

Auto

102 %

0-0.48

-0psi%

m3h

Auto

1.43 1.62 0.00

2.27

6.5163

5092

215TphPebbles Produced

Bat. 7

Bat. 9 Bat. 10

Bat. 11 Bat. 12

kW/Ton Linea 3

Bat. 8

33 %Sol

6

6985 kW

-0 m3h

PI PB Energy

6212

4359

60

PSI

% ruido

kW

TphPebbles Chancado

Estimado 13823

día

15093

noche

857 15093Real

Estimado 8527

día

13701

noche

543 13701Real

Estimado 42901

día

32245

noche

2619 32245Real

Resumen Planta Molienda25

4214 kW

6551

104

PSI

% ruido

22 % +100

6

7058 kW

7

10234 kW

0 % +100 14 % +100 20 % +100

1150 TphCorrea 1

77% Finos

698 TphCorrea 2

57% Finos

62% Finos

3566 TphCorrea 3

Sag 1

55

4kW

0 % +100

Sag 2

Sag 3

27 % +100

2

4358 kW

0 % +100

EXPERT_ON

EXPERT_ON

EXPERT_ON

Estimado 64888

día

61039

noche

3772 61039Real

Total Planta

5440Puntual

3

4001 kW

4125

1kW

7

7070

5

kW

228TphPebbles Produced

7696 kW

105ruido

0 ruido

90 Veloc.

813 psi850 psi

33

PI PB Concentrator

1

Espesador de Concentrado 1

70SP % Sol

7066

SP % SolPV % Sol

60PV % Sol

0 m3h

0 m3h

26 Amps

34 Amps

0.52 Nm4.08 Amps

0.01 pulgadas

3

2

1

Espesador de Concentrado 2

1500 SP % Sol

15001567

SP % SolPV % Sol

1385 PV % Sol

406 m3h

275 m3h

Bad InputAmps

Bad Input Amps% Vel

0.22 Nm3.47 Amps

0.08 pulgadas

5

4

4.58 Amps

Bad Input

34 % Sol

47 % Sol

20 SP lpm9 PV lpm

7.30 Ph

Espesador de Concentrado 3

1500 SP % Sol

1500500

SP % SolPV % Sol

1005 PV % Sol

-7 m3h

33 m3h

Bad InputAmps

1 AmpsHz

0.27 Nm2.66 Amps

0.06 pulgadas

2.53 Amps

46

-0

0

-1

SP % Sol

PV % Sol

Hz

8

9

Espesador 1

5

0

10

0

4

0

20

Espesadores de Concentrado

Tk Conc

Est. Conicos

997-0 m3/h

kg/m3

139430 m3/h

kg/m3

Espesador 2

5

0

10

0

10

0

4

0

24

Espesador 3

5

0

10

0

10

0

4

0

24

Bombas Descarga

50

0

100

Bombas Descarga

20

0

50

Bombas Descarga

20

0

50

PI Process Books

PipelineSFM1

SFM2

E.V. #1

E.V. #2

E.V. #4

1064

1116

2163

531

Alim Bombas

Presiones E V

Presiones E M

P. Nitrogeno

COM. OPTICA

PANEL SOLAR

SFM3

SFM4

E.V. #3

SFM3

COM. OPTICA

PANEL SOLAR

SFM4

COM. OPTICA

PANEL SOLAR

0

371

331

502

148

1664

LINEA DE 12"

LINEA DE 8"

# lub

C D

# lub900 257

A B

# lub785 785

A B

# lub588 600

A B

# lub831 906

A B

Filtros Coloso

165Presión Desc.

-0Flujo

1Solidos

98Presión Alim.

1314

1

0

62.94

Flujo

Presión Entrada

Solidos

Presión Salida

1315

0

0.00

1 Flujo

Presión Entrada

Solidos

Presión Salida

Concentrator

HistorianMine Control

Production SystemMine System

ERP II

Control System

Middleware

Vehicle

System

Laboratory

Mine Planning

Concentrator, Oxide, Coloso

PI

Servers

WENCO

Server

SIGPLAN

Server

SPM

Server

SAP

Servers

MIMS

Servers

Bailey

Servers

Bailey

Servers

Bailey

Servers

RLINK

Server

VIMS STATEX

LAB

Server

VULCAN

Servers

Systems Integration

GSAP

Systems Integration• Integration of Wenco and OSI PI – W2P

– Extract the Equipment Status & Location

– Determine Equipment Usage

– Transfer information from Oracle to PI

– Wenco to Receive Notification Number

• Integration of DCS and OSI PI

– Equipment Status transfer information from DCS to PI

– PI determines Equipment Usage

– PI to Receive Measurement Document and Notification Number

Systems Integration

• OSI PI to SAP PM Notification

– Equipment breakdown statuses trigger alarm

– RLINK PM monitors alarm and creates

notification for SAP PM Functional Location

for Equipment

– Returns Notification number to PI and Wenco

– Maintenance responds to notification

Maintenance Notification

Integration

DCS

PI

FLOW

FLOW

RLINK

PM

Plan

Measurement

Document

Work Order

SAP PM

Measurement

Document

Number

Measurement Document &

Notification Creation Request

•Functional Location/Equipment

•Code

•Location

Measurement

Document

Details

Work Instructions

Work Status

SAP PP

Plan

SAP MM

Plan

Notification

Details / StatusNotification

Details / Status

Maintain Flow

Dependent

Equipment

Notification

WENCO

SAG

Systems Integration• OSI PI to SAP PM Usage Measurement

– Equipment usage totalized per day

– RLINK PM monitors usage tags and creates

measurement document for SAP PM Functional

Location for Equipment based on periodic alarm trigger

– Returns measurement document number to PI

– SAP PM creates work orders based on measurement

document information

Maintenance Planning

Integration

DCS

PI

ON/OFF

ON/OFF

RLINK

PM

Plan

MD’s

WO’s

SAP PM

Alarm

Trigger &

Integrated

Run Hours

Measurement

Document

Number

Measurement

Document

Creation Request

Measurement

Document

Details

Work Instructions

Work Status

SAP PP

Plan

SAP MM

Plan

Maintain Pump

Assembly

NOT’sDCS

PI

ON/OFF

ON/OFF

RLINK

PM

Plan

Measurement

Document

Work Order

SAP PM

Alarm

Trigger &

Integrated

Run Hours

Measurement

Document

Number

Measurement

Document

Creation Request

Measurement

Document

Details

Work Instructions

Work Status

SAP PP

Plan

SAP MM

Plan

Maintain Pump

Assembly

Notification

WENCO

Implementation Plan

• Establish Requirements & Functionality Required

• Design the Integrated System

• Set up Development/Test Environment

• Design Pilot Configuration and Test

• Parameter Data Collection

• Design Configuration and Test all Parameter Data

• Set up Production Environment

• Transfer Configuration to Production

• GO-Live and Support!

WENCO

Server

W2P

Object

O2P

Interface

Concentrator, Oxide, Coloso

PI

Servers

Production

RLINK

Server

Bailey

Servers

Bailey

Servers

Bailey

ServersVIMS STATEX

Production

SAP

Environment

Environments

Development & Test

RLINK

Server

Development & Test

SAP

Environment

W2P

Object

O2P

Interface

RLINK Implementation

• Configuration steps!

– Identify Mine and Plant Equipment information sources

– Create Wenco to PI Database

– Configure Oracle to PI interface

– Create unique RLINK tag sets for usages and

notifications MINE and PLANT (alarms, value,

description)

– Create RLINK configuration for measurement and

notifications linking tag sets to SAP PM Functional

Locations

WENCO

Server

W2P

Object

O2P

Interface

Concentrator, Oxide, Coloso

PI

Servers

RLINK

Server

Bailey

Servers

Bailey

Servers

Bailey

Servers

VIMS STATEX

PI RLINK Tag Set

Configuration

SAP

Servers

SAP PM

ConfigurationOracle to PI

Configuration

RLINK

ConfigurationW2P

Configuration

Configuration

RLINK Implementation

• Examples of configuration files!

– Oracle to PI interface files – DAT and INI

– Mine Tag files – General and Specific Tags

– Plant Tag files – General and Specific Tags

– RLINK Configuration Mine and Plant files

RLINK Implementation

• Test configuration

– Configure SAP Test Environment

– Test fire triggers and verify correct system functionality

and data transfers

– Load test the system by generating many transfers

• Training

• Go Live

– Transfer configuration to Production Environment

– Monitor and support system

RLINK Implementation

• Project Team

– GSAP (Joe Gracia and team)

– Escondida Team (PI Ramon, Wenco Arturo, IT

Fernando)

– OSI USA Support (Gretchen, Ajoy)

– Hatch Integration (Cedric)

RLINK Implementation Tips

• Development/Test used for training

• Test all configuration changes on test

system

• Test all s/w patches on test system

• Backup all systems regularly

Travel Tips

• Carry some extra clothes in your hand

luggage

• Medicals, don’t think your local doctor

knows it all

• Don’t assume anything, test and make sure