UC2004 - Using PI for BSC Reporting at QNI · Using PI for BSC Reporting at QNI . OSI PI Users Conference 2004, San Francisco, April 2004 Page 2 ... Alarms PI-SQC Production MS-SQL

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


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


Page 4

Yabulu Refinery Overview

Water recycling

facility

3TP Nickel

Compacts


Page 5

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


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


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


Page 8

Yabulu Balanced Scorecard


Page 9

Example Business Unit Scorecard


Page 10

Production & Efficiency - Nickel Plant

Critical calciner KPI’s monitored in real-time


Page 11

Production & Efficiency - Roasters


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


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


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


Page 15


•Downtime summary report, using Crystal Reports

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


Page 16


Equipment tree and reason sets stored in PI-MDB


Page 17


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


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


Page 19


Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations


Page 20


Report on measured and reconciled mass through each meter

Report on data quality and quality of mass balance


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


Page 22

Environment & Community - Stack Discharges

Using SQC Chart Histogram for MTD KPI’s

Double clicking chart title bar display statistics


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


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


Page 25

Other Business Benefits - Updating BSC Using PI-ACE


Page 26

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


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 ?


Page 28

Questions ?

Documents

UC2004 - Using PI for BSC Reporting at QNI · Using PI for BSC Reporting at QNI . OSI PI Users Conference 2004, San Francisco, April 2004 Page 2 ... Alarms PI-SQC Production MS-SQL