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Using PI for BSC Reporting at QNI

Using PI for BSC Reporting at QNI. Dave Hunter Group Leader - Metallurgical Accounts, QNI Pty Ltd. Outline. Yabulu Refinery Overview. Business Systems Architecture. Yabulu Refinery Performance Measures. Other Business Benefits. Questions. Overview. P H I L I P P I N E S. Hinatuan.

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Using PI for BSC Reporting at QNI

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  1. Using PI for BSC Reporting at QNI Dave Hunter Group Leader - Metallurgical Accounts, QNI Pty Ltd

  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

  3. Overview P H I L I P P I N E S Hinatuan • 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 Taganito Rio Tuba Yabulu Ore Sources Gee Gebe I N D O N E S I A N E W C A L E D O N I A Baie Ugue Greenvale Karembe Kouaoua Yabulu Boakaine Teoudie Nakety Noumea A U S T R A L I A Brisbane OSI PI Users Conference 2004, San Francisco, April 2004

  4. 3TP Nickel Compacts Water recycling facility Yabulu Refinery Overview OSI PI Users Conference 2004, San Francisco, April 2004

  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 OSI PI Users Conference 2004, San Francisco, April 2004

  6. PIMS Business Systems Functional Hierarchy Sales & Marketing MSAP Accounting, Maintenance, HR, Supply QSAP Asset Mgt Activa Risk Mgt RMS2000 LMS Traccess LIMS CCLAS Production MS-SQL MSDS’s ChemAlert KPI & Advanced Calcs PI-ACE Alarms PI-SQC Incident Mgt First Priority Data Historian (OSI PI) Ore Ship & Train Scheduling G2 Reconciliation S-fine Forecasting MS Excel Plant Mass Balancing Metsim Expert System Connoisseur DCS System6 & PLC’s OSI PI Users Conference 2004, San Francisco, April 2004

  7. Crystal Reports LIMS SAP PI-RDBMS R/Link-PM PI-ODBC Intranet  Excel PI-ODBC PI-SDK PI-ODBC PI-RDBMS HTTP Σ Ø MSDS’s Statistica Weather Station Automatic PIMS Interfaces PIMS OSI PI Users Conference 2004, San Francisco, April 2004

  8. Yabulu Balanced Scorecard OSI PI Users Conference 2004, San Francisco, April 2004

  9. Example Business Unit Scorecard OSI PI Users Conference 2004, San Francisco, April 2004

  10. Production & Efficiency - Nickel Plant Critical calciner KPI’s monitored in real-time OSI PI Users Conference 2004, San Francisco, April 2004

  11. Production & Efficiency - Roasters OSI PI Users Conference 2004, San Francisco, April 2004

  12. Production & Efficiency - Roasters % of time temperature was within ±10°C of SP during the last 6 hours OSI PI Users Conference 2004, San Francisco, April 2004

  13. Production & Efficiency - Grinding Compare KPI’s between Shifts Peak power is purchased at higher rate than off-peak OSI PI Users Conference 2004, San Francisco, April 2004

  14. /SQL="select COUNT(*),0 from dtmPrimary where Equipment1 = '320' AND StartTime > ?;" P1='PE.680.TS.Today'/VL Production & Efficiency - Dryers Operator log for entering reasons for downtime events Uses PI Alarm tags as triggers, and events saved in SQL table OSI PI Users Conference 2004, San Francisco, April 2004

  15. 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

  16. Production & Efficiency - Dryers Equipment tree and reason sets stored in PI-MDB OSI PI Users Conference 2004, San Francisco, April 2004

  17. Production & Efficiency - Dryers Downtime Client (OCX control) Downtime monitor data flows PI Server RTDB -Trigger Tags SQL Server SQL DB Downtime Service MDB -Equipment Tree -Reason Sets -DB Connections Developer’s PC Configuration Tool (OCX Control) OSI PI Users Conference 2004, San Francisco, April 2004

  18. 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 Production & Efficiency - Metallurgical Accounting OSI PI Users Conference 2004, San Francisco, April 2004

  19. Production & Efficiency - Metallurgical Accounting Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations OSI PI Users Conference 2004, San Francisco, April 2004

  20. Report on data quality and quality of mass balance Production & Efficiency - Metallurgical Accounting Report on measured and reconciled mass through each meter OSI PI Users Conference 2004, San Francisco, April 2004

  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

  22. Double clicking chart title bar display statistics Environment & Community - Stack Discharges Using SQC Chart Histogram for MTD KPI’s OSI PI Users Conference 2004, San Francisco, April 2004

  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

  24. Other Business Benefits - Updating BSC Using PI-ACE 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 OSI PI Users Conference 2004, San Francisco, April 2004

  25. Other Business Benefits - Updating BSC Using PI-ACE OSI PI Users Conference 2004, San Francisco, April 2004

  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 OSI PI Users Conference 2004, San Francisco, April 2004

  27. QNI PIMS Scorecard J • How up to date is the production information published on our intranet ? K • At what level of detail do we compare performance ? L • What interval is performance data tracked ? J • Who has access to this data ? K • How do we collect downtime ? OSI PI Users Conference 2004, San Francisco, April 2004

  28. Questions ? OSI PI Users Conference 2004, San Francisco, April 2004

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