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
OSI PI Users Conference 2004, San Francisco, April 2004
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Overview
PHILIPPINES
• 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
OSI PI Users Conference 2004, San Francisco, April 2004
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Rio Tuba
Hinatuan
Taganito
Yabulu Ore Sources
Gee
Gebe
INDONESIA
NEW
CALEDONIA
Greenvale
Yabulu
Karembe
Teoudie
Baie Ugue
Kouaoua
Boakaine
Nakety
Noumea
AUSTRALIA
Brisbane
Yabulu Refinery Overview
Nickel
Compacts
3TP
Water
recycling
facility
OSI PI Users Conference 2004, San Francisco, April 2004
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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
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Business Systems Functional Hierarchy
Sales & Marketing
MSAP
Accounting, Maintenance, HR, Supply
QSAP
Asset Mgt
Activa
Risk Mgt
RMS2000
PIMS
LIMS
CCLAS
LMS
Traccess
Production
MS-SQL
MSDS’s
ChemAlert
KPI & Advanced Calcs
PI-ACE
Reconciliation
S-fine
Alarms
PI-SQC
Data Historian
(OSI PI)
Incident Mgt
First Priority
Forecasting
MS Excel
Ore Ship & Train
Scheduling
G2
Plant Mass
Balancing
Metsim
Expert System
Connoisseur
DCS
System6 & PLC’s
OSI PI Users Conference 2004, San Francisco, April 2004
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Automatic PIMS Interfaces
Crystal
Reports
LIMS
Intranet
PI-RDBMS
PI-ODBC
PI-ODBC
PIMS
SAP
R/Link-PM
PI-SDK

Excel
PI-ODBC
Σ
Statistica
OSI PI Users Conference 2004, San Francisco, April 2004
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HTTP
MSDS’s
PI-RDBMS

Weather
Station
Yabulu Balanced Scorecard
OSI PI Users Conference 2004, San Francisco, April 2004
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Example Business Unit Scorecard
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Nickel Plant
Critical calciner KPI’s monitored in real-time
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Roasters
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Roasters
Monthly Average Hearth Hit Rate
60
Actual
Target
58
%
56
54
52
% of time temperature
was within ±10°C of SP
during the last 6 hours
OSI PI Users Conference 2004, San Francisco, April 2004
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50
48
Jul-03
Aug-03
Sep-03
Oct-03
Nov-03
Dec-03
Jan-04
Feb-04
Production & Efficiency - Grinding
Compare KPI’s between Shifts
Peak power is purchased at higher rate than off-peak
Hours Both Ball Mills Running
160
140
Peak Power
Off-Peak Power
120
hours
100
80
60
40
20
0
A
B
C
Shift
OSI PI Users Conference 2004, San Francisco, April 2004
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D
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
OSI PI Users Conference 2004, San Francisco, April 2004
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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
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Production & Efficiency - Dryers
Equipment tree and reason
sets stored in PI-MDB
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Dryers
•Downtime monitor data flows
Downtime Client
(OCX control)
PI Server
RTDB
SQL Server
-Trigger Tags
MDB
Downtime
Service
-Equipment Tree
-Reason Sets
Developer’s PC
-DB Connections
Configuration
Tool (OCX Control)
OSI PI Users Conference 2004, San Francisco, April 2004
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SQL DB
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
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Metallurgical Accounting
Flowsheet in
Sigmafine used
for monthly
nickel and cobalt
reconciliations
OSI PI Users Conference 2004, San Francisco, April 2004
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Production & Efficiency - Metallurgical Accounting
Report on measured and
reconciled mass through each
meter
Report on data quality and
quality of mass balance
OSI PI Users Conference 2004, San Francisco, April 2004
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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
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Environment & Community - Stack Discharges
Using SQC Chart Histogram for MTD KPI’s
Double clicking chart title bar display statistics
OSI PI Users Conference 2004, San Francisco, April 2004
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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
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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
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Other Business Benefits - Updating BSC Using PI-ACE
OSI PI Users Conference 2004, San Francisco, April 2004
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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
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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
K
• Who has access to this data ?
• How do we collect downtime ?
OSI PI Users Conference 2004, San Francisco, April 2004
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Questions ?
OSI PI Users Conference 2004, San Francisco, April 2004
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