David Fisk - Honeywell Grenn Holden - Honeywell

Transcription

1 A Few Ideas for Operational Excellence 2013 Honeywell Users Group Americas David Fisk - Honeywell Grenn Holden - Honeywell 1

2 2 Mining Operations - Goal

3 Mining Operations Reality? GOAL ACTUAL? 3

4 Safety 4 OF TODAY S BIG CHALLENGES Equipment failure & operator mis-handing Equipment availability and costs Unplanned downtime Emergency work is 4x the cost of planned work Production What is where and what is it? Information Availability/Decision Support 4

5 Equipment Availability and Cost Traditional Maintenance Program Operate on time based PM Fix it if it breaks between PMs Does not account for environment or abuse or monitor for abnormal wear between scheduled PMs. Does not highlight developing faults that are not picked up at PM 5

6 Equipment Availability and Cost State of the art today: Most industries have well developed condition monitoring programs for production equipment Equipment failure in a refinery can have some pretty serious consequences. Even my family car tells me when I need to change the oil 6

7 7 MEM Fleet Overview - Truck Overview

8 Mobile Equipment Monitoring (MEM) Data Access (wireless) Alarm data Sensor Data Other vehicle systems Tire, Lube, Fuel, GPS Monitoring Functions Equipment Health Operator Performance Production Alerts & Notifications Standard & custom/user defined rules notifications Alarm Viewer & Alarm Help Trending & Analysis Reporting Performance Bad Actors 8

9 Alarm & Event Handling Alarm Statistics Alarm Summary 9

10 Full Site Monitoring Tools Mobile Equipment Monitor 10

11 MEM and Safety Real time monitoring impact on safety Operator behaviour Monitor speeds at sensitive areas Operator report cards Monitor potential failure modes that affect safety Hydraulic pumps Brake temps 11

12 Belt AIS Conveyor Monitoring High-Speed Hi-Res Camera Self-contained and sealed w/ hi-speed strobe Hi-speed & resolution to cover moving belt Analysis Software Defect identification (Intensity & location) Video review, commenting & reports 12

13 What is where and what is it? 2 nd Challenge is Production Management What in in process inventory do we have, and what is the quality? What can we produce? How well are we doing? 13

14 Honeywell Production Manager A web-based Plant Information Management System Collects and presents plant operational data for both reporting and analysis 14

15 Downtime Reporter Monitors plant data to identify and analyze downtime events in real time. Tracks both plant stoppages and production shortfalls Supplements EAM 15

16 Downtime Report Benefits Automated Downtime Recording Accurate, Timely and Reliable Downtime classification using predefined codes Consistent, Managed and Contextual Secure role-based access Centralised data store, change traceability Increased plant performance and availability Root Cause Failure Analysis Asset Performance benchmarking Enable targeted improvement strategies 16

17 Production Module Automatic plant data collection and production reporting Collect and organize KPI s for each critical operating area Improve response times to non conformance events 17

18 Lab and Metallurgical Reporting. Collect and present grades/samples and other metallurgical data in real time Identify Non conformances and 19

19 Plan Manager Integrates with Mine Planning System Reports on: Planning targets (monthly, weekly, daily) Plant activity planning (Maint, Prod, Non-Prod, ) Baselines (Budget, Forecast, Plan) Crewing and roster management Reports Planned Vs. Actual Daily Production Plan Monthly Production Plan 20

20 Materials Manager Provides current stockpile tonnes and quality Automatically updates stockpile zones with tonnes, material type and tonnes weighted qualities. Manual adjustments, Accepts late-bound lab assays Reports Transaction History Stockpile Summary Tonnes and quality History Adjustments log 21

21 Train Manager Manages train scheduling and loading details Automatic update for schedule changes and wagon unload weights Records train and wagon times such as arrive, start and end. Download train consist for automated wagon batch loading Records train downtimes and provides cause classification Reports Berth and Ship Summary Train Loading Summary Train Loading Details Train Consignment Details Wagon type loading statistics 22

22 Matrikon 3D Stockpile Manager Precise 3D visibility of stockpile layout, mass and quality distribution. Stacking blocks 1m 3 based on first principles Bucket wheel, portal reclaiming etc supported Stacking & Reclaiming based on real-time movements Quality distribution Stockpile details 23

23 Information Availability: Integrated Operations 24

24 A tradition of overcoming the tyranny of distance 25 The Earth has been girdled as it were with a magic chain The Earth has been girdled as it were with a magic chain Sir Sir Hercules Robinson, Governor of of New New South South Wales

25 Remote Operations - New Operating Philosophy The capability to monitor and manage operational activities in real-time or near-time, regardless of location Innovative 26 Customers have transformed their businesses for true bottom line benefits

26 Remote Operations Centers Overcoming Distance Corporate Management Corporate Structure Mine A Site Management Mine B Site management Load & Haul Crush/ Convey Supply Chain Mill Flotation Inventory/ Ship; Load & Haul Crush/ Mill Convey Flotati on Inventor y/ship; Mine C Load & Haul Site management Crush/ Mill Convey Flotati on Inventor y/ship; 27

27 Integrated Operations Centers A new way to organize an operation Collaboration between people, across disciplines, companies and places Truly integrated Multidiscipline teams Distribution of internal & external information and knowledge Better use of scarce resources A dynamic organization Distributed real time working Has reduced decision time and improved decision making Is the way you add value from Integrated Operations 28

28 Drivers for Remote Collaboration Centers Productivity & Costs Increasing competitiveness -driven by performance analysis Staff Retention & Hiring Knowledge building & retention -Skilled & diverse people resources are in demand Integrated Operations Improved results -via collaboration & coordination Safety Reduce incidents -less people on site Safety Compliance -better monitoring & incident management 29

29 Case Study: Copper mining - Codelco Chuquicamata Chile Remote Monitoring and Support Center - Santiago Andina El Teniente Monitoring & Remote Access Centralized platform support Process Performance Analysis and Support Advanced Application support and tuning Facilities Access Control Training Outcomes Improved Throughput (2%) Improved Recovery (1.75%) Lower Process Variability + standardization, improved staffing, energy efficiency, preventive maintenance, personnel safety, benchmarking 30 Overcoming old work paradigms to achieve new operational horizons

30 Offshore Oil Production - Shell Exception Based Surveillance Built on Four Pillars Advanced Alarming Workflow Orchestration Situational Awareness & Visibility Knowledge Management 31 Rigorous and consistent surveillance, with as-needed escalation

31 Work in Process Alcoa Quasar - Australia Casserones Integrated Operations Chile Peabody Collaboration Center Project 32

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33 Thank You! Questions? David Fisk Director Global Sales - Mining Solutions (905)

34 2013 Honeywell Users Group Americas Advances in Equipment Monitoring Grenn Holden 35

35 MEM Update Agenda Recently Released MEM R New Alarm Viewer Documentation of Saves Execution Manager Roadmap Update R141 Focus R150 Direction Customer Advisory Board Next steps in Customer Involvement 36

36 New Alarm Viewer Ease of Use Managing Floods Historical Review 37

37 Capture Key Wins Provide Save Justification Documentation of Saves Approval and Reporting Options 38

38 Execution Manager Data Driven Analytics Analytic Orchestration Scalability 39

39 R141 Focus Java 7 and Internet Explorer 9 Support Java Stability Improvements System Heath Monitoring October 2013 Release 40

40 R150 Direction User Defined Event Authoring and Propagation Unified Configuration Dashboard and Reporting Enhancements Mid 2014 Release 41

41 Thank You! Questions? Grenn Holden Operations Manager - MEM (780)