Presented by

An OSIsoft Product Information Management System

Mark O’Meara

• Calculations based on real-time data are accurate and timely

• Manual entry and Excel sheets are being reduced

Solution Results and Benefits

Grange OSIsoft PIMS

Business Challenge• Centralise multiple

datasources• Replace many and varied

complex Excel workbooks• Provide a reliable solution• Realtime Information

• OSIsoft PI• PI Interfaces (Citect, UFL)• PI Client Tools (Process

Book, Coresight, Datalink)• Reports• Event Frames

“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 BramichManager Downstream Quality and Process Improvement

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

component of the PIMS

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• 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 2028.

• 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.

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Process Overview

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Savage River Port Latta

(Diagram reference: http://www.magnetitenetwork.com.au/who-we-are/magnetite/)

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…

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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

– %

PIMS

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PI Server• Data sources • PI Interfaces• Architecture Overview• Reliability

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• Version 7.3• At Savage River &

Port Latta sites• Hot failover

redundancy arrangement

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Excel !!

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Excel• Usage

– Shift Reports– Production Statistics– Laboratory Results– Delays

• What data points can be collected automatically? Which require manual input and calculation?

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Interfaces• PI Citect API Interface

– OPC also an option• Pros & Cons of OPC vs ct API

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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

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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

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Architecture

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High Availability

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PI Asset Framework• Planning• Structure• Attributes & Elements

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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

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Categories• How can users best find their

data?

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Element Templates

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Inherit attributes

Plant Hierarchy• Physical and or

logical• Use reference links

where appropriate

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Calculations• Replicate Excel

formulas within AF• Complexity within

AF in order to leverage intuitive client tools (Coresight)

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Power Monitoring• Overview• PI Notifications

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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

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Power Price Calculation• Create SQL Stored Procedures

– Duration and Time in Advance as parameters

– Result is the average predicted price for that period.

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Integration• SCADA used for alarming and

operator action• PI System used for management

review and management notification (email)

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PI Notifications

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Send email to Distribution

Group

Lab & Manual Data• PI Manual Logger

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PI Manual Logger

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High Availability

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Operational Monitoring• Overview• Event Frames• Data References• KPI• Reporting and PI

OLEDB Enterprise

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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

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Event Frames• Used to provide time

context to the data– E.g. Shift

• Aim– Self contained– Leverage integration

with Osisoft client tools when available

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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

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Data References• Data References can be

customised where appropriate

• Check out vCampus whitepaper for Implementing AF Data References.

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KPI• KPI Event Frame

summarises Downtime, Production, Quality, Event Frame data

• Uses a custom data reference

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PI OLEDB Enterprise• Used to

– Provide SQL access to PI System and AF Data (including Event Frames)

– Transpose Event Frames

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Reports• Using Microsoft SQL Server

Reporting Services• Automated email to

subscribers• Summarise Production and

Environmental Data

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Osisoft Client Tools• PI SQC Client• Process Book• Coresight

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PI SQC Client

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• Used in the Control Room• Keeps Operators

informed about the quality of concentrate in pipeline and quality of pellets produced

Process Book

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• Grange staff have found the client easy to configure, use and deploy.

• Extensive use of the Osisoft YouTube Learning Channel

Coresight• Quick tool for trending

of data• Display of Lab Results• Display of KPI’s• Ship loading

information for Lab

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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

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© Copyr igh t 2013 OSIso f t , LLC.

Mark OMearamark.om@cromarty.com.auCromarty

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