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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. - PowerPoint PPT PresentationTRANSCRIPT
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
• 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
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
Pit
Leaching
Concentrator
Port Coloso
Concentrator
ColosoLoader
Truck Fleet
Process Overview
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
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
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
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
ConcentratorHistorian
Mine Control
Production SystemMine System
ERP II
Control System
VehicleSystem
Laboratory
Mine Planning
Concentrator, Oxide, ColosoPI
Servers
WENCO Server
SIGPLAN Server
SPM Server
SAP Servers
MIMS Servers
Bailey Servers
Bailey Servers
Bailey ServersVIMS STATEX
LAB Server
VULCAN Servers
Systems Overview
GSAP
PI PB Concentrator
Cola Ro
0.5
0
1
CANALETA
20
30
40
0
60
0
150
3000
7000
0
40
A
45
-0
A44
A47
Cajón Reruteo
50
0
90
Flotación Rougher
Cajón de Reruteo
Cajón 12 Vías
0
80
0
50
8
40
0
50
0
50
0
50
0
50
0
50
Alimentación Rougher
Ley Alimentacion
2
1
3
15
40
320.05
320.05320.05
%SolFeCu
Linea 1
Linea 2
Linea 3
Linea 4
Linea 5
Linea 6
Linea 7
Linea 8
Tonelajes
2000
4000
0
80001162
3599698 Sag 2
Sag 1
Sag 3
5507 Total
1.51
36.711.63 Fe
Cu
%Sol
HighAlarm
5
4
6
4
6
0
4
0
4
0
4
0.88 Rec Rou
47 Canaleta
Ph Rougher
10
9
12
9
12
9
12
9
12
9
12
0
12
9
120.00 Ph Rougher
A0 A122 A130
PC8
G2-EB
PC1
PC2
PC3
PC4
PC5
PC6
PC7
10.40
10.35
10.39
10.50
PI PB Grinding Line
0
90
7
10273
0.40 10.26
0
1200
12
10
9
1416
11 1
A% %
72 A
171 A
-0 A216 A
11
m3h
kW
3489 Tph
8 7
9 10
1112
% +100
58psi psi
25 TphPebbles Retornados
Alimentación
LINEA 3 DE MOLIENDA 3/5/2002 8:15:46 AM intermedia
1448 m3h
1003m3h
770 m3h78 %Sol
1201m3h
23 m3h
Experto Sag 3 Lub. Sag 3 PSI´s
0 A
1317378
A%
8036 kW845 psi
106ruido
0 ruido91 Veloc.
814 psi
33
% +10064% Finos Correa
CASCADA
EXPERT_ON EXPERT_ON
Sag 1 Sag 2 Retorno
7 8 9 10
Pebbles
Alimentadores 7 8 9 10
30
100
84
35
60
45
0
90
56 88
Cajón Sag 3
Cajón Bolas 5
Cajón Bolas 6 Cajón Bolas 7
% +100 23
17
12
0-0.04 psi
%
-2 m3h
4928 m3h
52565.90
53
0 m3h 6712 m3h
776 PSI 780 PSI
317 m3h
85 m3h
7
%Sol %Sol
1500
A%
100 %
AutoAutoAuto
70695 kW
51 m3h
Manual
Auto
Auto
102 %
0-0.48
-0psi%
m3h
Auto
1.43 1.62 0.00
2.27
6.5163
5092
215TphPebbles Produced
Bat. 7
Bat. 9 Bat. 10
Bat. 11 Bat. 12
kW/Ton Linea 3
Bat. 8
33 %Sol
6
6985 kW
-0 m3h
PI PB Energy
6212
4359
60
PSI
% ruido
kW
TphPebbles Chancado
Estimado 13823
día
15093
noche
857 15093Real
Estimado 8527
día
13701
noche
543 13701Real
Estimado 42901
día
32245
noche
2619 32245Real
Resumen Planta Molienda25
4214 kW
6551
104
PSI
% ruido
22 % +100
6
7058 kW
7
10234 kW
0 % +100 14 % +100 20 % +100
1150 TphCorrea 177% Finos
698 TphCorrea 257% Finos
62% Finos3566 TphCorrea 3
Sag 1
554
kW
0 % +100
Sag 2
Sag 3
27 % +100
24358 kW
0 % +100
EXPERT_ON
EXPERT_ON
EXPERT_ON
Estimado 64888
día
61039
noche
3772 61039Real
Total Planta
5440Puntual
34001 kW
41251
kW
7
7070
5
kW
228TphPebbles Produced
7696 kW
105ruido
0 ruido90 Veloc.
813 psi850 psi
33
PI PB Concentrator
1
Espesador de Concentrado 1
70SP % Sol
7066
SP % SolPV % Sol
60PV % Sol
0 m3h
0 m3h
26 Amps
34 Amps
0.52 Nm4.08 Amps
0.01 pulgadas
3
2
1
Espesador de Concentrado 2
1500 SP % Sol
15001567
SP % SolPV % Sol
1385 PV % Sol
406 m3h
275 m3h
Bad InputAmps
Bad Input Amps% Vel
0.22 Nm3.47 Amps
0.08 pulgadas
5
4
4.58 Amps
Bad Input
34 % Sol
47 % Sol
20 SP lpm9 PV lpm
7.30 Ph
Espesador de Concentrado 3
1500 SP % Sol
1500500
SP % SolPV % Sol
1005 PV % Sol
-7 m3h
33 m3h
Bad InputAmps
1 AmpsHz
0.27 Nm2.66 Amps
0.06 pulgadas
2.53 Amps
46
-0
0-1
SP % SolPV % Sol
Hz
8
9
Espesador 1
5
0
10
0
4
0
20
Espesadores de Concentrado
Tk Conc
Est. Conicos
997-0 m3/h
kg/m3
139430 m3/h
kg/m3
Espesador 2
5
0
10
0
10
0
4
0
24
Espesador 3
5
0
10
0
10
0
4
0
24
Bombas Descarga
50
0
100
Bombas Descarga
20
0
50
Bombas Descarga
20
0
50
PI Process BooksPipelineSFM1
SFM2
E.V. #1
E.V. #2
E.V. #4
1064
1116
2163
531
Alim Bombas
Presiones E V
Presiones E M
P. Nitrogeno
COM. OPTICAPANEL SOLAR
SFM3SFM4
E.V. #3
SFM3
COM. OPTICAPANEL SOLAR
SFM4
COM. OPTICAPANEL SOLAR
0
371
331
502
148
1664
LINEA DE 12"
LINEA DE 8"
# lub
C D
# lub900 257
A B
# lub785 785
A B
# lub588 600
A B
# lub831 906
A B
Filtros Coloso
165Presión Desc.
-0Flujo
1Solidos
98Presión Alim.
1314
1
0
62.94
Flujo
Presión Entrada
Solidos
Presión Salida
1315
0
0.00
1 Flujo
Presión Entrada
Solidos
Presión Salida
ConcentratorHistorian
Mine Control
Production SystemMine System
ERP II
Control System
Middleware
VehicleSystem
Laboratory
Mine Planning
Concentrator, Oxide, ColosoPI
Servers
WENCO Server
SIGPLAN Server
SPM Server
SAP Servers
MIMS Servers
Bailey Servers
Bailey Servers
Bailey Servers
RLINK Server
VIMS STATEX
LAB Server
VULCAN Servers
Systems Integration
GSAP
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
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
Maintenance Notification Integration
DCS
PI
FLOW
FLOW
RLINK
PM Plan
MeasurementDocument
Work Order
SAP PM
Measurement DocumentNumber
Measurement Document & Notification Creation Request•Functional Location/Equipment•Code•Location
Measurement DocumentDetails
Work Instructions
Work Status
SAP PP Plan
SAP MM Plan
Notification Details / StatusNotification
Details / Status
Maintain Flow Dependent Equipment
Notification
WENCO
SAG
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
Maintenance Planning Integration
DCS
PI
ON/OFF
ON/OFF
RLINK
PM Plan
MD’s
WO’s
SAP PM
Alarm Trigger &Integrated Run Hours
Measurement DocumentNumber
Measurement DocumentCreation Request
Measurement DocumentDetails
Work Instructions
Work Status
SAP PP Plan
SAP MM Plan
Maintain Pump Assembly
NOT’sDCS
PI
ON/OFF
ON/OFF
RLINK
PM Plan
MeasurementDocument
Work Order
SAP PM
Alarm Trigger &Integrated Run Hours
Measurement DocumentNumber
Measurement DocumentCreation Request
Measurement DocumentDetails
Work Instructions
Work Status
SAP PP Plan
SAP MM Plan
Maintain Pump Assembly
Notification
WENCO
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!
WENCO Server
W2PObject
O2PInterface
Concentrator, Oxide, ColosoPI
Servers
ProductionRLINK Server
Bailey Servers
Bailey Servers
Bailey ServersVIMS STATEX
ProductionSAP
Environment
Environments
Development & TestRLINK Server
Development & TestSAP
Environment
W2PObject
O2PInterface
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
WENCO Server
W2PObject
O2PInterface
Concentrator, Oxide, ColosoPI
Servers
RLINK Server
Bailey Servers
Bailey Servers
Bailey Servers
VIMS STATEX
PI RLINK Tag Set Configuration
SAP Servers
SAP PM ConfigurationOracle to PI
Configuration
RLINK ConfigurationW2P
Configuration
Configuration
RLINK Implementation
• Examples of configuration files!
– Oracle to PI interface files – DAT and INI
– Mine Tag files – General and Specific Tags
– Plant Tag files – General and Specific Tags
– RLINK Configuration Mine and Plant files
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
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)
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
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