update on pi system development & enterprise … · update on pi system development &...
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© Copyr i gh t 2014 Ang l o Am er i c an Ch i l e
L tda .
Presented by
Update on PI System
Development & Enterprise
Agreement experience at
Anglo American Copper
Fernando Romero
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Anglo American plc. a global mining company.
Business strategy.
Business challenge.
The solution.
Project development with an OSIsoft Enterprise Agreement.
Conclusions.
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AGENDA
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .3
STRATEGIC COMMODITIES WORLDWIDE
Operating Profit:
( US$ millions )
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .4
Anglo American Copper
Copper belongs to Base Metals BU of AA plc.
Chile (6 Operations) & Peru (2 Greenfield Projects)
2013 results:
Operating profit: US$ 1,739 millions (26%)
EBITDA: US$ 2,402 millions, ROCE: 25%
Production Cu fine: 775 [kton]
Average number of own Employees: 4,200
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
COPPER CURRENT PORTFOLIO: OPERATIONS
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• Open pit mine in Central Chile producing
concentrate & cathodes.
• Production 416 kt Cu plus Mo & Ag in 2013.
• Mine life > 30 years.
• Significant upside potential at San Enrique
Monolito and Los Sulfatos.
• Non-managed open pit mine in Northern
Chile producing concentrate & cathodes.
• Production 196 kt Cu (44%) plus Mo & Ag in
2013.
• Mine life > 30 years.
• Significant potential for further expansions.
• Open pit mine in Northern Chile producing
concentrate & cathodes.
• Production 55 kt Cu plus Ag in 2013.
• Mine life 10 years with potential for extension.
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
COPPER CURRENT PORTFOLIO: OPERATIONS
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• Open pit, heap leach mine in Northern Chile
producing cathodes.
• Production 57 kt Cu in 2013.
• Mine life 6 years with potential for life
extension through sulphide processing.
• Open pit mine in Central Chile producing
concentrate & cathodes.
• Production 52 kt Cu plus Ag in 2013.
• Mine life 20 years.
• Cu smelter in Central Chile, primarily treating
concentrate from Los Bronces and El
Soldado.
• Production 145 kt anodes/blister Cu plus
503 kt sulphuric acid in 2013.
• Potential to expand production.
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
AngloAmerican Strategy: “One Anglo” model
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Ambition: To Be the Leading Global Mining Company
Wh
ere Employer of ChoiceInvestment of Choice Partner of Choice
Guiding Values
• Safety
• Care and Respect
• Integrity
• Accountability
• Collaboration
• Innovation
Wh
o
The One Anglo Culture
People making a difference in a Company making a difference
Drivers
Common Systems
and Processes
Agree to what we do
An Effective
Organisation
Ensure we can do it
Operational
Excellence
Do it+ +
Develop Build Deliver
Ho
w
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
The need of real-time information management for
Operational Excellence, Safety & Sustainability
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PI System in AA Copper
Business Challenge:
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
An integrated approach considering
Process Control & Automation (PC&A) plus Information Technologies (IT)
for Assets Optimisation and Business Improvement
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Technical solution:
PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
It is necessary to define
a model and architecture for
information integration in real-time.
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
From Data to
Information
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PROCESS
DATA BASES
(RELATIONAL)
SENSORS
ACTUA-
TORS
AUTOMATIC
CONTROL
ALGORITHM
(REAL TIME)
PROCESS DATA
VALIDATION &
RECONCILIATION
OPTIMISING
ALGORITHM
(REAL TIME)
PROCESS
MODEL
(REAL TIME)
OPTIMISING
ALGORITHM
BUSINESS
MODEL
M
M
PROCESS
DATA BASES
(REAL TIME)
AUTOMATIC
DATA
AUTOMATIC
ACTIONS
OPERATOR
MANUAL
MEASUREMENT
RELATIONAL
DATA BASES
MANUAL
DATA
OTHER SOURCES
OF INFORMATION
REAL TIME
INFO
OPERATIONAL
INFORMATION
BUDGETING &
PLANNING
INFO
PROCESS
PROCESS
INFORMATION
REAL TIME
INFORMATION MANAGEMENT
(ISA S95 Levels 1, 2 & 3)
TRANSACTIONAL
INFORMATION MANAGEMENT
(ISA S95 Levels 4 & 5)
•Laboratory
•Observations
•Other measurements
SP*
SP
AUTOMATIC
DECISIONS
SP : low level set-point
SP* : high level set-point
ASSETS MODEL
BUSINESS
INFORMATION
Fernando RomeroManager Process Control
Anglo American Chile
Anglo Copper BU
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Information Integration Model
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Plants
Ancillary Systems
Mine Planning &
SchedulingDatamine / Minesight
Tonnage, Weight, Levels, Flow, Current, Power, Temperature, Pressure, Oresize, Alarms, Calculation, Rate, Deviation, Mean, Consumption, etc.
GeologyAcQuire / Datamine
SurveyESRI / Autodesk
ERP – Ellipse / SAP
Finance &
Costing Procurement
Inventory &
Warehousing
ERP - SAP
HR & Payroll
Sonic ESB & ETL Integration
CataloguesLinkOne
SCM
MarketplaceQuardrem & e-
hub Connect
Mining Opencast
Energy
Management
System(DigSilent, others)
Maintenance Production
SD/HSECAnglo Safe
Budgeting &
PlanningHyperionEngineering
Autodesk
Operational Modeling &
OptimisationCarbon E
Condition – Based
Maintenance System(Matrikon, HPS-AM)
DIVISION - PROCESS OPERATIONS MANAGEMENT (OSIsof t PI System)
LE
VE
L 1
Measu
rem
en
ts
CORPORATE PROCESS INFORMATION SYSTEM (OSIsof t PI System )
Process
Control System
(DCS´s – PLC’s)
Advanced Control
& Expert System
(Supervisory MPC, APC)
Fleet Management
System
(Dispatch, Jigsaw)
Equipment Health
Monitoring System
(VIMS – VHMS - Others)
Maintenance
Laboratoty Information
Management System
(Starlims, CCLAS)
Distribution
Monitoring &
Control System
(SCADA’s)
Instruments & Sensors
Geology
Real Time
Data Bases
Data Collection
SystemsMonitoring &
Analysis System(Vibration, Pressure,
Temperature)
Quality
Quality & Assay
Management Systems
(Assay Management)
Outbound
Logistics (MineMarket)
Sales
Management
(Minemarket - TSW)
Weighing System
& Route Waybills(E-Truck / SGD)
Technical Support Systems
Metal
Accounting
(Production Accounting)
ProductionData
Collection
ProductionTracking
ProductionPerformance
Analysis
Power & Energy
Sampling &
Analysis Systems
(LAB´s Instr.& Assay)
Environmental
Management
System(SMA, Water, Others)
Environmental
Monitoring
System
(SVACH)
Environment & Water
LE
VE
L 2
Un
its
Co
ntr
ol
LE
VE
L 3
Op
era
tio
ns
Man
ag
em
en
t
LE
VE
L 4
Bu
sin
ess P
lan
nin
g
& M
an
ag
em
en
tBased on
ISA S95 &
ISA S88
standards
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
OSIsoft PI System:
• Single platform to integrate all data from the Operations Value Chain.
• Enabling infrastructure to develop value applications in real-time.
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Real-time Operations Management
PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Project Development (from 2011): Key facts
• Multidisciplinary team:Owner (PC&A + IM + Operations) + System Integrator (Contac Ingenieros) + OSIsoft.
• Standardized and robust design in H/W & S/W.
• Availability of communications networks (three tiers architecture):– Process networks (Control)
– Industrial networks (IIT)
– Commercial network (Corporate)
• Connection to all process & equipment data sources.
• Real-time Data Base (RTDB) modeling based on assets: PI AssetFramework (PI AF).
• OSIsoft Enterprise Agreement: Unlimited licensing, EPM assigned to the Project, CoE consultancy, NOC support
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Three tiers
networks
architecture
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PI System in AA Copper
Software
PI High
Availability
SoftwareSQL Server
PI AF
PI Notifications
PI ACE
Software
PI High
Availability
Software
PI ProcessBook
PI DataLink
Software
SQL Server
PI AF
PI Notifications
PI ACE
Software
SharePoint
Server
PI WebParts
DCS / PLC /SCADA
Control Systems
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Project Development: Original situation in 2010
• Mantos Blancos:No PI System, no IIT network.
• Mantoverde:No PI System, no IIT network.
• El Soldado:Small PI System (2,000 tags), 15 Clients, no IIT network.
• Chagres Smelter:PI System (15,000 tags), 9 Clients, no IIT network.
• Los Bronces:Small PI System, 3 Servers (5,000; 2,000; 2,000 tags), 36 Clients (concurrent), no IIT network.
• Santiago (Head Offices)No PI System, no IIT network.
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Project Development: 2011 - 2012
Platform (H/W & S/W) procurement, installation and commissioning in all sites exceptSantiago. Remote software installations from NOC.
IIT network engineering, project approval, procurement and start of construction in allsites.
PI System database configuration in all sites. All tags from Process Control Networks (PLCs, DCSs), Laboratory Systems, SCADAs, other relational databases.
Operational Portals and Reports in each site. Design, configuration and roll-out byContac Ingenieros Ltda. (Systems Integrator).
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Project Development: 2011 - 2012
On-site training for administrators and key users including PI AF.
Continuous support from EPM: periodic meetings (weekly status calls).
Modeling based on assets using PI AF (design under review).
Three Workshops with CoE in Santiago: PI AF, Sustainability (Energy Management), Conditions Based Maintenance (CBM).
Platform monitoring services from NOC.
Several custom applications developed by users: «information democracy».
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Project Development: 2013 - 2014
• 2013: start-up of IIT networks in all sites.
• 2014: Corporate PI System (Headquarters).
• Value Applications based in PI AF– Local and Global Energy Management System.
– CBM Center of Excellence.
– Improved Reportability and Business Intelligence.
• Large-scale training (empowering people).
• Operational Information Delivery (OID) standarized among Copper Operations.
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Economic Benefits (as Project estimation):
• Increase in the availability of processesand equipments: 0.2%
• Increase in Energy Efficiency: 1%
• Decrease of Maintenence Costs: 1%
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Other Benefits:
• Process analysis.
• Unique reporting (one version of the truth).
• Lower complexity in applications
management.
• Easy access to information.
• Sharing best practices among different
operations.
• Value applications development.
• Key enabler for Integrated Operations
Management Centres (IOMC).
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Conclusions
Alignment with Company Strategy.
It’s all about people.
Multidisciplinary Project.
Broad scope: from technical issues to change management (cultural
change).
Democracy and standardization of information across processes.
OSIsoft EA to keep pace on development, help to define the
roadmap and provide the infrastructure: strategic partner.
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PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Information for collaboration and decision making.
… collaboration and decision making for Operational Excellence.
… Operational Excellence to be the Investment of Choice.
… Investment of Choice to be the Leading Global Mining Company.
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“People making a difference in a Company making a difference”
PI System in AA Copper
© Copyr i gh t 2014 Ang l o Am er i c an
Ch i l e L tda .
Fernando Romero
Manager Process Control
Anglo American Copper
Chile
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