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RLINK PM

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.

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RLINK PM

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Presentation Transcript

  1. RLINK PM BHP-Billiton Escondida Presenter: Cedric Luyt

  2. Overview • Process Overview • Maintenance Requirements & Design • Systems Overview • Systems Integration • RLINK Implementation • Project Tips

  3. Map

  4. 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

  5. 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

  6. Pit

  7. Leaching

  8. Concentrator

  9. Port Coloso

  10. Truck Fleet Concentrator Process Overview Loader Coloso

  11. 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

  12. 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

  13. 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

  14. 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

  15. Systems Overview ERP II Mine Planning SPM Server SIGPLAN Server Mine System Production System Laboratory Mine Control Concentrator Historian Bailey Servers Bailey Servers Bailey Servers Vehicle System Control System SAP Servers MIMS Servers GSAP VULCAN Servers LAB Server WENCO Server Concentrator, Oxide, Coloso PI Servers VIMS STATEX

  16. PI PB Concentrator

  17. PI PB Grinding Line

  18. PI PB Energy

  19. PI PB Concentrator

  20. PI Process Books

  21. Systems Integration ERP II Mine Planning SPM Server SIGPLAN Server Mine System Production System Middleware Laboratory Mine Control Concentrator Historian Bailey Servers Bailey Servers Bailey Servers Vehicle System Control System SAP Servers MIMS Servers GSAP VULCAN Servers RLINK Server LAB Server WENCO Server Concentrator, Oxide, Coloso PI Servers VIMS STATEX

  22. 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

  23. 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

  24. SAG Maintenance Notification Integration Measurement Document & Notification Creation Request • Functional Location/Equipment • Code • Location Measurement Document Details SAP MM Plan WENCO Measurement Document Number PI RLINK SAP PM Measurement Document FLOW Notification Details / Status PM Plan Notification Details / Status DCS Notification Work Instructions FLOW Work Order SAP PP Plan Maintain Flow Dependent Equipment Work Status

  25. 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

  26. Measurement Document Creation Request Measurement Document Details Alarm Trigger & Integrated Run Hours Measurement Document Number SAP MM Plan PI RLINK SAP PM Measurement Document ON/OFF PM Plan DCS Notification Work Instructions ON/OFF Work Order SAP PP Plan Maintain Pump Assembly Work Status Maintenance Planning Integration Measurement Document Creation Request Measurement Document Details Alarm Trigger & Integrated Run Hours Measurement Document Number WENCO SAP MM Plan PI RLINK SAP PM MD’s ON/OFF PM Plan DCS NOT’s Work Instructions ON/OFF WO’s SAP PP Plan Maintain Pump Assembly Work Status

  27. 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!

  28. Environments Bailey Servers Bailey Servers Bailey Servers Development & Test SAP Environment Production SAP Environment Development & Test RLINK Server Production RLINK Server W2P Object O2P Interface Concentrator, Oxide, Coloso PI Servers WENCO Server W2P Object O2P Interface VIMS STATEX

  29. 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

  30. Configuration Bailey Servers Bailey Servers Bailey Servers SAP PM Configuration Oracle to PI Configuration SAP Servers RLINK Configuration W2P Configuration RLINK Server WENCO Server W2P Object O2P Interface Concentrator, Oxide, Coloso PI Servers PI RLINK Tag Set Configuration VIMS STATEX

  31. RLINK Implementation • Examples of configuration files! • Oracle to PI interface files – DAT and INI • Mine Tag files – General and Specific Tags • Plant Tag files – Generaland Specific Tags • RLINK Configuration Mine and Plant files

  32. 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

  33. 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)

  34. 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

  35. 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

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