deploying a common pi infrastructure across …€¦ · deploying a common pi infrastructure across...

Presented by

© Copyr igh t 2013 OSIso f t , LLC.

Deploying a common PI Infrastructure across

Barrick Gold- Asia Pacific

CASE STUDY: Rolling out a Regional Data Historian

Presented by: Gavin StrackManager - Process ControlBarrick Australia Pacific

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Case Study

Rolling out a regional data historian

Case Study

Rolling out a regional data historian

August 2013August 2013

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Barrick OverviewBarrick Overview

Copyright Barrick Gold 2013

A leading gold producer

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Barrick Australia PacificBarrick Australia Pacific


Perth

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Our systemsOur systems


EmersonRockwell

RosemountSchneiderYokogawa

RockwellSchneider

RosemountRockwell

YokogawaSiemens

Schneider

Yokogawa

GESchneider

InvensysSiemensIDEC

YokogawaPEP

Perth

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Our historians - 2012Our historians - 2012


PI System

Nil

PI System Exaquantum

Nil

PI System

Nil

Nil

Perth

Nil

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Corporate StandardsCorporate Standards


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Project InitiationProject Initiation

• Scope and plan developed

• Project Scope:• New infrastructure at Darlot, Lawlers, Granny Smith,

Plutonic and Perth• Upgrade of the existing PI System data historians at

Kanowna Belle

• Iterative approach to develop a standard IT-OT interfaceCopyright Barrick Gold 2013

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IT-OT Standard InterfaceIT-OT Standard Interface


Signed:Chief Operating Officer

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Construction updateConstruction update

Perth Perth

2012 2013


Funding method to be confirmed.

Funding method determined.

Under construction.

Infrastructure in place.

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Our historiansOur historians


PI System

PI System

PI System Exaquantum

PI System

PI System

PI System

PI System

Perth

PI System Blue sites are Integrated into regional replicated PI Server in

Perth

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How could we add value?How could we add value?


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Remote connectivityRemote connectivity

Visibility of the process from any computer connected to the Barrick Intranet


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Offsite EnablementOffsite Enablement

Perth Reliability Engineering• Offsite investigation of crusher failure• Enabled informed and defendable

discussions with the vendor during warranty claim

Perth Process Control• Offsite investigation of PLC/SCADA

communications error• Enabled fault rectification via phone

within minutes instead of days


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Setting up automatic reportingSetting up automatic reporting


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Improved OperationsImproved Operations

Automatic Production Reporting• Production achieved• Asset/plant area performance• Statistical analysis (e.g. +/- 3σ)• No OT access required


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UnderstandingPowerUnderstandingPower


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Improving Process UnderstandingImproving Process Understanding


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Improved MaintenanceImproved Maintenance

Automatic Run-hours Reporting• Equipment run-hours collated and reported• Run-hours report automatically imported into MIS• Manual data entry errors removed• Unplanned failures due to planned maintenance not being

done reduced

PC1‐3111‐31001CR02.M001 05:08:2013 00:00:00 45665.3Run Hours ‐ Crusher Jaw Primary Jaques Absolute H AscendingPC1‐3151‐31001CR03.M001 05:08:2013 00:00:00 44935.64Run Hours ‐ Crusher Cone Secondary Absolute H AscendingPC1‐3161‐31001CR04.M001 05:08:2013 00:00:00 42676.89Run Hours ‐ Crusher Cone Tertiary No1 Absolute H AscendingPC1‐3161‐31001CR05.M001 05:08:2013 00:00:00 43305Run Hours ‐ Crusher Cone Tertiary No2 Absolute H AscendingPC1‐3152‐31001FA01.M001 05:08:2013 00:00:00 47398.63Run Hours ‐ Collector Fan Dust Absolute H AscendingPC1‐3151‐31001FA03.M001 05:08:2013 00:00:00 20381.14Run Hours ‐ Fan Radiator Cooling Secondary Absolute H AscendingPC1‐3161‐31001FA04.M001 05:08:2013 00:00:00 22543.13Run Hours ‐ Fan Radiator Cooling Tert No1 Absolute H AscendingPC1‐3161‐31001FA05.M001 05:08:2013 00:00:00 27217.71Run Hours ‐ Fan Radiator Cooling Tert No2 Absolute H Ascending


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Improved MaintenanceImproved Maintenance

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7Process Maintenance ‐ Call Outs

Mechanical SI

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100%Mill Availability and Utilisation

Actual Utilisation Actual Availability Target AvailabilityCopyright Barrick Gold 2013

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Optimisation EnablementOptimisation Enablement

Process Optimisation• Mass balance modelling using real process data• Opportunities are identified and quantified easily

t/h % Sol (w/v)

GRINDING CIRCUIT MASS BALANCE MODEL 06:00 104.9 Instrument faulty

Model is based on a mixture of process measurement and calculated values. t/h 12:00 107.8 Instrument faulty06:00 104.9 18:00 103.9 Instrument faulty

DATE: 3-Jul-13 12:00 107.8 23:59 104.9 Instrument faultyEnter the date for the PI Historian data you wish to use. kPa 18:00 103.9

06:00 69 23:59 104.9Massflows are dry solids 12:00 72 kPa

18:00 65 06:00 110t/h CLR 23:59 64 12:00 125

06:00 248.6 237% 18:00 12212:00 260.8 242% 23:59 14618:00 249.5 240% PCYC SCYC23:59 224.8 214% # in use 1 # in use 3

t/h % Sol (w/v) t/h % Sol (w/v)06:00 353.5 73.8% t/h CLR 06:00 514.8 72.1%12:00 368.6 73.5% 06:00 409.9 391% 12:00 542.1 71.2%18:00 353.4 75.6% 12:00 434.3 403% 18:00 545.9 71.9%23:59 329.6 74.0% 18:00 442.0 425% 23:59 497.2 71.3%

PBM 23:59 392.4 374%

SBM

t/h06:00 104.912:00 107.818:00 103.923:59 104.9

kW06:00 581

kW t 12:00 58806:00 1064 76.1 18:00 58012:00 1064 75.8 23:59 58118:00 1066 75.623:59 1065 76.3

AssumptionsSolids SG 2.8Water SG 1.0Solids % moisture 2.0%


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Improvement Opportunity ExampleImprovement Opportunity Example

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tt/h%

kWA

Primary Ball Mill

PM_KW_PV PBM Current PBM Weight PBM Feed Rate PBM Feeder SpeedMill Power

Feed Rate


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Business Case DevelopmentBusiness Case Development

Feb-Apr 2013 data ~ 17,000t loss @ 115t/h (69 KTPA) 4g/t head grade (2012) 93.5% Recovery (2012) ~300 oz

Benefit is ~$400k p.a. maintaining 115t/h Indicative project cost: $150k. Payback is ~ 4 months.

If we lift tonnes, its pure profit.


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Improved Optimisation ImplementationImproved Optimisation Implementation

• Process modelling


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Improved Process VisualisationImproved Process Visualisation

• Process visibility anywhere• No SCADA licenses• Visibility without control – reduced risk• Standardise process visualisation regionally


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Typical HMI ExampleTypical HMI Example


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New HMI ExampleNew HMI Example


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New HMI ExampleNew HMI Example


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Human Centred HMI DesignHuman Centred HMI Design


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“The Vision”“The Vision”

Crushing Grinding Flotation Leaching Elution Tails

+$$$


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Now imagine it regionally?Now imagine it regionally?


Region

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Process Value Chain PrototypeProcess Value Chain Prototype

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Crushing Grinding Leaching Tailings

Processing Value Chain‐ Last 24 Hours

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Crushing Grinding Leaching Tailings

Processing Value Chain‐ Last 7 days


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Process Value Chain PrototypeProcess Value Chain Prototype


Building the normalised report in PI Asset Framework (AF)– Captures business intelligence in

PI AF– Avoids “Excel Hell”

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“One data infrastructure, one language and one set of common tools” ‐ Vision“One data infrastructure, one language and one set of common tools” ‐ Vision

PI Infrastructure and common tools provide benefits:– All speaking the same language.

– Moving forward on multiple fronts for plant optimisation and efficiency – some using PI System and others automation/process projects.

– We are chasing $2 million improvements this year…

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SummarySummary

We can integrate our disparate systems We can see what is happening at remote operations from anywhere We can quantify opportunities using real data and validate improvements are

delivered We can make life easier for the operator, and focus their efforts on adding

value Our process data is secure, accessible, auditable and traceable

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“Insanity: doing the same thing over and over again and expecting different results.”

- Albert Einstein

Questions?Questions?


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