How To Use A Powerpoint To Improve Your Productivity

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Brianne Maxwell
3 years ago
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1 Presented by An OSIsoft Product Information Management System Mark O Meara

2 Grange OSIsoft PIMS Personnel have been making the right decisions based on the right information. Concentrate physical targets have been adjusted based on informed decisions to balance throughput and quality against plan. Grant Bramich Manager Downstream Quality and Process Improvement Business Challenge Centralise multiple datasources Replace many and varied complex Excel workbooks Provide a reliable solution Realtime Information Solution OSIsoft PI PI Interfaces (Citect, UFL) PI Client Tools (Process Book, Coresight, Datalink) Reports Event Frames Results and Benefits Calculations based on realtime data are accurate and timely Manual entry and Excel sheets are being reduced 2

Grant Bramich Manager Downstream Quality and Process Improvement Business Challenge Centralise multiple datasources Replace many and varied complex Excel workbooks Provide

3 Agenda About Grange Resources Overview of the PIMS How the PI System is used to form each component of the PIMS 3

4 Grange Resources Limited owns and operates Australia's largest integrated iron ore mining and pellet production business located in the northwest region of Tasmania. The Savage River magnetite iron ore mine, 100km southwest of the city of Burnie, is a long life mining asset set to continue operation to 2023 with current reserves estimated to extend the mine life to At Port Latta, 70kms northwest of Burnie, is Grange Resources' wholly owned pellet plant and port facility producing approximately two million tonnes of premium quality iron ore pellets annually with plans to increase annual production in the coming years to 2.7 million tonnes. 4

The Savage River magnetite iron ore mine, 100km southwest of the city of Burnie, is a long life mining asset set to continue operation to 2023 with current

5 Process Overview Savage River Port Latta (Diagram reference: 5

6 Port Latta Process Overview What to monitor? Filter Operation Furnace Production Rate & Operation Particulate Emissions Quality Variables AEMO Power Costs What to Control? Water Addition Bentonite Addition Gas & Coal Usage Feed Rates And more 6

Particulate Emissions Quality Variables AEMO Power Costs

7 Quality Variables Concentrate - Physical Grind & Blaine Concentrate - Chemical Fe (Iron) Fe ++ Mg0 (Magnesium Oxide) Si02 (Silica) S (Sulphur) Pellet Quality AI Covers a relative measure of the resistance of iron ore pellets and sinter to degradation by impact and by abrasion %<5mm Pellets less than target size CCS Compression strength of the pellet when cool Process Interruptions (especially if causing heat variation in furnace) 7

iron ore pellets and sinter to degradation by impact and by abrasion %<5mm Pellets less than target size CCS

8 PIMS 8

9 PI Server Data sources PI Interfaces Architecture Overview Reliability 9

10 Version 7.3 At Savage River & Port Latta sites Hot failover redundancy arrangement 10

11 Excel!! 11

12 Excel Usage Shift Reports Production Statistics Laboratory Results Delays What data points can be collected automatically? Which require manual input and calculation? 12

13 Interfaces PI Citect API Interface OPC also an option Pros & Cons of OPC vs ct API 13

14 UFL Used to import Excel & Database data from multiple sources into PI Transitionary, allowed each datasource to be replaced by PI System, tested and accepted. Backfill CitectScada trend data 14

15 Architecture Requirements Efficient long term storage life of mine Promotes data sharing between the sites Highly reliable Interface to the available data sources Simple access to client tools Solid platform for future expansion 15

Highly reliable Interface to the available data sources

16 Architecture 16

17 High Availability 17

18 PI Asset Framework Planning Structure Attributes & Elements 18

19 Planning What is the data being represented? Attributes What equipment is it associated with? Elements Consistency in UOM How to represent the equipment within a structure? Plant hierarchy Security 19

Elements Consistency in UOM How to represent the

20 Categories How can users best find their data? 20

21 Element Templates Inherit attributes 21

22 Plant Hierarchy Physical and or logical Use reference links where appropriate 22

23 Calculations Replicate Excel formulas within AF Complexity within AF in order to leverage intuitive client tools (Coresight) 23

24 Power Monitoring Overview PI Notifications 24

25 Overview Ensure profitable production by monitoring predicted AEMO power price One hour notification to management and operator power price > $ MWh for a duration > 30 min forecasted 60 min in advance Half hour warning to operator >$ MWh for a duration > 30 mins forecasted 30 min in advance Five minute Alarm to operator and action advice >$ MWh for a duration > 30 mins forecasted 15 min in advance 25

26 Power Price Calculation Create SQL Stored Procedures Duration and Time in Advance as parameters Result is the average predicted price for that period. 26

27 Integration SCADA used for alarming and operator action PI System used for management review and management notification ( ) 27

28 PI Notifications Send to Distribution Group 28

29 Lab & Manual Data PI Manual Logger 29

30 PI Manual Logger 30

31 High Availability 31

32 Operational Monitoring Overview Event Frames Data References KPI Reporting and PI OLEDB Enterprise 32

33 Overview Production Statistics Greenfeed/Pellets Produced Gas Usage Coal Usage Bentonite Usage Compared to target Downtime and Rate Loss Furnace Coal System Pelletiser Filters Quality & Environmental Time away from quality Emissions beyond threshold KPI s Availability, Quality, Production, etc 33

34 Event Frames Used to provide time context to the data E.g. Shift Aim Self contained Leverage integration with Osisoft client tools when available 34

35 Event Frame - Structure Standard Fields Start Time, End Time, Referenced Element, Duration, Category Categorisation Fields Shift Name, Crew, Relative Date Contexts (e.g. Start of Shift, Start of Production day) Data Fields Pellets Produced Production Rate Production Target Formula Fields Production Loss Effective Duration 35

36 Data References Data References can be customised where appropriate Check out vcampus whitepaper for Implementing AF Data References. 36

37 KPI KPI Event Frame summarises Downtime, Production, Quality, Event Frame data Uses a custom data reference 37

38 PI OLEDB Enterprise Used to Provide SQL access to PI System and AF Data (including Event Frames) Transpose Event Frames 38

39 Reports Using Microsoft SQL Server Reporting Services Automated to subscribers Summarise Production and Environmental Data 39

40 Osisoft Client Tools PI SQC Client Process Book Coresight 40

41 PI SQC Client Used in the Control Room Keeps Operators informed about the quality of concentrate in pipeline and quality of pellets produced 41

42 Process Book Grange staff have found the client easy to configure, use and deploy. Extensive use of the Osisoft YouTube Learning Channel 42

43 Coresight Quick tool for trending of data Display of Lab Results Display of KPI s Ship loading information for Lab 43

44 Conclusion The PI System enables Reduced reliance on Excel for data entry and reporting Automated data collection Sophisticated Data Analysis tools Centralised data store Architecture that allows simple and quick sharing of data between sites 44

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