Using PI for BSC Reporting at QNI Dave

Using PI for BSC Reporting at QNI Dave Hunter Group Leader - Metallurgical Accounts, QNI Pty Ltd

Outline • Yabulu Refinery Overview • Business Systems Architecture • Yabulu Refinery Performance Measures • Other Business Benefits • Questions OSI PI Users Conference 2004, San Francisco, April 2004 2

Overview PHILIPPINES Yabulu Ore • BHPBilliton’s Sources nickel business Gee Gebe • Operations in Australia and Colombia INDONESIA • World’s 5 th largest NEW CALEDONIA nickel and cobalt Baie Ugue Greenvale producer Karembe Kouaoua Yabulu Boakaine Teoudie • 3. 5 M tpa of Nakety Noumea AUSTRALIA imported ore Brisbane produces 32 000 T Ni and 2000 T Co • Employs 700 OSIpeople PI Users Conference 2004, San Francisco, April 2004 Rio Tuba 3 Hinatuan Taganito

Yabulu Refinery Overview Nickel Compacts 3 TP Water recycli ng facility OSI PI Users Conference 2004, San Francisco, April 2004 4

Yabulu Refinery Overview cont. . . 6 Control Rooms Mixture of Different Control Systems PI installed November 2000 • Administered by IT Department • Champions in each Business Unit Refinery BSC Reporting Implemented FY 03 OSI PI Users Conference 2004, San Francisco, April 2004 5

Business Systems Functional Hierarchy Sales & Marketing MSAP Accounting, Maintenance, HR, Supply QSAP Asset Mgt Activa Risk Mgt RMS 2000 PIMS LIMS CCLAS LMS Traccess Production MS-SQL MSDS’s Chem. Alert KPI & Advanced Calcs PI-ACE Reconciliation S-fine Alarms PI-SQC Data Historian (OSI PI) Incident Mgt First Priority Forecasting MS Excel Ore Ship & Train Scheduling G 2 Plant Mass Balancing Metsim Expert System Connoisseur DCS System 6 & PLC’s OSI PI Users Conference 2004, San Francisco, April 2004 6

Automatic PIMS Interfaces Crystal Reports LIMS Intranet PI-RDBMS PI-ODBC PIMS SAP R/Link-PM PI-SDK Excel PI-ODBC Σ Statistica HTTP MSDS’s OSI PI Users Conference 2004, San Francisco, April 2004 7 PI-RDBMS Ø Weather Station

Yabulu Balanced Scorecard OSI PI Users Conference 2004, San Francisco, April 2004 8

Example Business Unit Scorecard OSI PI Users Conference 2004, San Francisco, April 2004 9

Production & Efficiency - Nickel Plant Critical calciner KPI’s monitored in real-time OSI PI Users Conference 2004, San Francisco, April 2004 10

Production & Efficiency - Roasters OSI PI Users Conference 2004, San Francisco, April 2004 11

Production & Efficiency - Roasters % of time temperature was within ± 10°C of SP during the last 6 OSI PI Users Conference 2004, San Francisco, April 2004 12 hours

Production & Efficiency - Grinding Compare KPI’s between Shifts Peak power is purchased at higher rate than off -peak OSI PI Users Conference 2004, San Francisco, April 2004 13

Production & Efficiency - Dryers Operator log for entering reasons for downtime events Uses PI Alarm tags as triggers, and events saved in SQL table /SQL="select COUNT(*), 0 from dtm. Primary where Equipment 1 = '320' AND Start. Time > ? ; " P 1='PE. 680. TS. Today'/VL OSI PI Users Conference 2004, San Francisco, April 2004 14

Production & Efficiency - Dryers • Downtime summary report, using Crystal Reports • Adhoc reports executed from Excel / MS Query for maintenance reporting OSI PI Users Conference 2004, San Francisco, April 2004 15

Production & Efficiency - Dryers Equipment tree and reason sets stored in PIMDB OSI PI Users Conference 2004, San Francisco, April 2004 16

Production & Efficiency - Dryers • Downtime monitor data flows Downtime Client (OCX control) PI Server RTDB SQL Server -Trigger Tags MDB Downtime Service -Equipment Tree -Reason Sets Developer’s PC -DB Connections Configuration Tool (OCX Control) OSI PI Users Conference 2004, San Francisco, April 2004 17 SQL DB

Production & Efficiency - Metallurgical Accounting Sigmafine used to perform monthly reconciliations for nickel and cobalt Allows flowsheet mass balance to identify unmeasured losses Input data can be read from PI tags or csv file Has allowed monthly Metallurgical Accounting reports to be completed in 1 working day Report on intrinsic data quality i. e. meter & weigher accuracy OSI PI Users Conference 2004, San Francisco, April 2004 18

Production & Efficiency - Metallurgical Accounting Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations OSI PI Users Conference 2004, San Francisco, April 2004 19

Production & Efficiency - Metallurgical Accounting Report on measured and reconciled mass through each meter Report on data quality and quality of mass balance OSI PI Users Conference 2004, San Francisco, April 2004 20

Profitability & Growth - Project ROI Calculate payback from improvement projects by writing current nickel & cobalt prices to PI tags, and using in Data Sets OSI PI Users Conference 2004, San Francisco, April 2004 21

Environment & Community - Stack Discharges Using SQC Chart Histogram for MTD KPI’s Double clicking chart title bar display statistics OSI PI Users Conference 2004, San Francisco, April 2004 22

Health & Safety - CRO Logs • Operator names recorded in PI string tags • Safety & training stats and text saved in SQL Server • PI Trend showing tank levels for duration of shift OSI PI Users Conference 2004, San Francisco, April 2004 23

Other Business Benefits - Updating BSC Using PI-ACE used to write monthly measures to BSC database connection string stored as property in MDB BSC Measure tags saved as aliases in MDB Measure. ID stored in “User. Int 1” tag attribute OSI PI Users Conference 2004, San Francisco, April 2004 24

Other Business Benefits - Updating BSC Using PI-ACE OSI PI Users Conference 2004, San Francisco, April 2004 25

Other Business Benefits - Process Capability for ISO 9001 For a process that is normally distributed it is known that 99. 73% of all values are within the ± 3 sd around the mean Review data which falls outside this range to determine the cause. Exclude this data if the process was unstable Calculate process capability based on a 95% confidence level around the process mean This is what we know the process is currently capable of achieving. Configure PI-RTSQC Alarms for when process goes outside these control limits, and raise incident in First. Priority OSI PI Users Conference 2004, San Francisco, April 2004 26

QNI PIMS Scorecard J • How up to date is the production information published on our intranet ? K • At what level of detail do we compare performance ? • What interval is performance data tracked ? L J K • Who has access to this data ? • How do we collect downtime ? OSI PI Users Conference 2004, San Francisco, April 2004 27

Questions ? OSI PI Users Conference 2004, San Francisco, April 2004 28