Using PI for BSC Reporting at QNI

Transcription

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 Page 2

3 Overview P H I L I P P I N E S 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 T Ni and 2000T Co Employs 700 people Rio Tuba Hinatuan Taganito Gee Gebe I N D O N E S I A A U S T R A L I A Yabulu Ore Sources Greenvale Yabulu Brisbane N E W C A L E D O N I A Karembe Teoudie Noumea Baie Ugue Kouaoua Boakaine Nakety Page 3

4 Yabulu Refinery Overview Nickel Compacts 3TP Water recycling facility Page 4

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 5

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

7 Automatic PIMS Interfaces Crystal Reports SAP LIMS PI-RDBMS PI-ODBC R/Link-PM Intranet PI-ODBC PIMS PI-SDK Excel Σ Statistica PI-ODBC HTTP MSDS s PI-RDBMS Weather Station Page 7

8 Yabulu Balanced Scorecard Page 8

9 Example Business Unit Scorecard Page 9

10 Production & Efficiency - Nickel Plant Critical calciner KPI s monitored in real-time Page 10

11 Production & Efficiency - Roasters Page 11

12 % Production & Efficiency - Roasters Monthly Average Hearth Hit Rate Actual Target % of time temperature was within ±10 C of SP during the last 6 hours Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Jan-04 Feb-04 Page 12

13 hours Production & Efficiency - Grinding Compare KPI s between Shifts Peak power is purchased at higher rate than off-peak Hours Both Ball Mills Running Peak Power Off-Peak Power A B C D Shift Page 13

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 14

15 Production & Efficiency - Dryers Downtime summary report, using Crystal Reports Adhoc reports executed from Excel / MS Query for maintenance reporting Page 15

16 Production & Efficiency - Dryers Equipment tree and reason sets stored in PI-MDB Page 16

17 Production & Efficiency - Dryers Downtime monitor data flows PI Server Downtime Client (OCX control) RTDB -Trigger Tags MDB -Equipment Tree -Reason Sets -DB Connections Downtime Service Developer s PC Configuration Tool (OCX Control) SQL Server SQL DB Page 17

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 18

19 Production & Efficiency - Metallurgical Accounting Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations Page 19

20 Production & Efficiency - Metallurgical Accounting Report on measured and reconciled mass through each meter Report on data quality and quality of mass balance Page 20

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 21

22 Environment & Community - Stack Discharges Using SQC Chart Histogram for MTD KPI s Double clicking chart title bar display statistics Page 22

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 23

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 Page 24

25 Other Business Benefits - Updating BSC Using PI-ACE Page 25

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 26

27 QNI PIMS Scorecard J K L J K How up to date is the production information published on our intranet? 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 27

28 Page 28 Questions?