Update on PI System Development & Enterprise Agreement experience...

© 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.

2

AGENDA


Ch i l e L tda .3

STRATEGIC COMMODITIES WORLDWIDE

Operating Profit:

( US$ millions )


Ch i l e L tda .4


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


Ch i l e L tda .

COPPER CURRENT PORTFOLIO: OPERATIONS

5

• 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


• Production 55 kt Cu plus Ag in 2013.

• Mine life 10 years with potential for extension.


Ch i l e L tda .

COPPER CURRENT PORTFOLIO: OPERATIONS

6

• 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


• 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.


Ch i l e L tda .

AngloAmerican Strategy: “One Anglo” model

7

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


Ch i l e L tda .8

Anglo American Copper Strategy


Ch i l e L tda .

The need of real-time information management for

Operational Excellence, Safety & Sustainability

9

PI System in AA Copper

Business Challenge:


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

10

Technical solution:



Ch i l e L tda .

It is necessary to define

a model and architecture for

information integration in real-time.

11



Ch i l e L tda .

From Data to

Information

12

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


Ch i l e L tda .

Information Integration Model

13

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


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



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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Ch i l e L tda .

Three tiers

networks

architecture

16


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


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.

17



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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Ch i l e L tda .


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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Ch i l e L tda .


• 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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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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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).

22



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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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”



Ch i l e L tda .

Fernando Romero

[email protected]

Manager Process Control


Chile

25

mailto:[email protected]

Update on PI System Development & Enterprise Agreement experience...

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