2013 Honeywell Users Group Americas

1

A Few Ideas for Operational Excellence

David Fisk - Honeywell

Grenn Holden - Honeywell

2

Mining Operations - Goal

3

Mining Operations – Reality?

GOAL ACTUAL?

4

4 OF TODAY’S BIG CHALLENGES

• Safety – 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

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

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

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MEM Fleet Overview - Truck Overview

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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’

• E-mail notifications

• Alarm Viewer & Alarm Help

• Trending & Analysis

• Reporting • Performance

• Bad Actors

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Alarm & Event Handling

Alarm Statistics

Alarm Summary

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Full Site Monitoring Tools

Mobile

Equipment

Monitor

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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

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

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What is where and what is it?

• 2nd 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?

14

Honeywell Production Manager

A web-based Plant Information Management System

Collects and presents plant operational data for both reporting and analysis

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Downtime Reporter

• Monitors plant data to

identify and analyze

downtime events in

real time.

• Tracks both plant

stoppages and

production shortfalls

• Supplements EAM

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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

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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

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Lab and Metallurgical Reporting.

• Collect and present grades/samples and other metallurgical data in real time

– Identify Non conformances and

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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

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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

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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

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Matrikon 3D Stockpile Manager

• Precise 3D visibility of

stockpile layout, mass and

quality distribution.

• Stacking blocks 1m3 based

on first principles

• Bucket wheel, portal

reclaiming etc supported

• Stacking & Reclaiming

based on real-time

movements

Quality distribution

Stockpile details

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Information

Availability:

Integrated

Operations

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A tradition of overcoming the ‘tyranny of

distance’

“The Earth has been girdled as it were with a magic chain” Sir Hercules Robinson, Governor of New South Wales 1872

“The Earth has been girdled as it were with a magic chain” Sir Hercules Robinson, Governor of New South Wales 1872

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Remote Operations - New Operating

Philosophy

The capability to monitor and manage

operational activities in real-time or

near-time, regardless of location

Innovative Customers have transformed their businesses for true bottom line benefits

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Remote Operations Centers – Overcoming

Distance

Site

Management

Site

management

Site

management

Corporate

Management

Supply

Chain

Co

rpo

rate

Stru

ctu

re

Mine A

Mine B

Mine C Load &

Haul

Mill Flotation Inventory/

Ship;

Crush/

Convey Load

&

Haul

Mill Flotati

on

Inventor

y/Ship;

Crush/

Convey

Load

&

Haul

Mill Flotati

on

Inventor

y/Ship;

Crush/

Convey

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• 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

Integrated Operations Centers

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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

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Case Study: Copper mining - Codelco Chuquicamata

Andina

El Teniente

Chile Remote Monitoring and Support Center - Santiago

•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

Overcoming old work paradigms to achieve new operational horizons

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Offshore Oil Production - Shell Exception Based

Surveillance

Built on Four Pillars

• Advanced Alarming

• Workflow

Orchestration

• Situational

Awareness &

Visibility

• Knowledge

Management

Rigorous and consistent surveillance, with as-needed escalation

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Work in Process

• Alcoa Quasar - Australia

• Casserones – Integrated Operations – Chile

• Peabody Collaboration Center Project

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David Fisk

Director Global Sales - Mining Solutions

(905)608-6388

http://www.honeywellprocess.com

Thank You! – Questions?

2013 Honeywell Users Group Americas

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Advances in Equipment Monitoring Grenn Holden

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MEM Update Agenda

• Recently Released – MEM R140.1.1

– New Alarm Viewer

– Documentation of Saves

– Execution Manager

• Roadmap Update

– R141 Focus

– R150 Direction

• Customer Advisory Board

– Next steps in Customer Involvement

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New Alarm Viewer

• Ease of Use

• Managing Floods

• Historical Review

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Documentation of Saves

• Capture Key Wins

• Provide Save

Justification

• Approval and Reporting

Options

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Execution Manager

• Data Driven Analytics

• Analytic Orchestration

• Scalability

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R141 Focus

• Java 7 and Internet Explorer 9 Support

• Java Stability Improvements

• System Heath Monitoring

• October 2013 Release

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R150 Direction

• User Defined Event Authoring and Propagation

• Unified Configuration

• Dashboard and Reporting Enhancements

• Mid 2014 Release

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Grenn Holden

Operations Manager - MEM

(780)448-1010

http://www.honeywellprocess.com

Thank You! – Questions?