Transcript Slide 1

Migrating from Exaquantum to PImaking the most of hard earned
history
David Carr
Oceanagold Limited
OCEANIA
OCEANIA
OCEANIA
TECHNOLOGY
TECHNOLOGY
TECHNOLOGY
SEMINAR
SEMINAR
SEMINAR
2008
20082008
© 2008
© 2008
OSIsoft,
OSIsoft,
Inc. |Inc.
Company
| Company
Confidential
Confidential
1
Introduction
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Company background
Drivers for change
Migration plan
Outcomes
Obtaining value from history
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About Oceanagold
• Largest Gold producer in New Zealand
– 180,000oz pa over last 4 years
– Forecasting >280,000oz in 2008
• Listed on the Toronto, ASX and NZX
• 2 operating mines in NZ 800km apart
– Reefton, West Coast producing 75,000 oz in
pyrite concentrate
– Macraes, Otago producing 220,000oz from local
ore and processing Reefton concentrate
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Macraes Site
• Commenced operations in 1990 treating 1.5Mtpa
• 2007 throughput 5.7Mtpa
• Complex metallurgical process plant
– 2 stage Grinding circuit
– sulphide flotation
– Pressure oxidation
– Carbon in Leach
– Concentrate repulp and regrinding facility
• Extensive circuit development over the last 10 years to increase
throughput and maximise recovery
– Commissioning first M1000 Isamill in May 07
– Commissioning worlds largest flotation cells –Outotec 300m3 Nov 07
– Autoclave capacity and debottlenecking critical to maximising cashflow
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Macraes Site
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Existing Systems
• Yokogawa CS3000 DCS since 2005
– Upgraded from hybrid CS1000 and uXL system
• Exaquantum PIMS system installed in 2002
– Installed for long term trending
– Plant reporting and logsheets
• Pronto XI for Purchasing, Maintenance, GL
• Numerous Access & Excel files for lab
results & reporting
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Issues with existing PIMS
• Disk space usage – 85MB/day for 2000
points
• Speed of response
• Data retrieval speed slow
• Local support not available
• Significant issues with each upgrade
• Trending tool unfriendly to novice users,
slow to configure displays
• Windows Domain Authentication
• Poor acceptance and utilisation of data
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Goals from shifting to PI
• Collect instrument data from DCS
• Collect Alarm & Event data from DCS
• Migrate existing history into PI Archive
– 130GB of instrument data over last 5 years
• Automate alerts via email/SMS
• Remote access to data via Citrix
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Proof of Concept
• Test system set up on site
– OPC interface configured to CS3000 system
– OPC A&E interface configured to CS3000
system
– PI-EqCtr COM Connector established to
Exaquantum system
– Email alerts set up using PI-ACE and Module
database
– Electronic logsheets rewritten & expanded for PI
– Manual/lab data captured through VBA in Excel
– History migrated from Exaquantum to PI for test
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Equipment used
• Leading edge server hardware
• Secure location
• Controlled environment
Compaq laptop P4 1.6Mhz
750MB RAM
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Implementation plan
• Based on success of test system approval
to proceed with base system
– 3,000 tag base server
– PI-ACE for reporting automation
– Processbook/Datalink client software
• IT Department sourced server hardware
– HP-DL360 Blade Server
• Utilise existing PC hardware for clients and
API node
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Migration method-Receiving Server
• Take point database from demonstration
system
• Install PI Server on a spare machine with
date set to 2002
• Create points from test system, turn
compression off
• Stop PI, set time to trial system start and
force archive shift
• Delete “empty” archive from 2002-2007
• Create fixed archives for intervening time
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Migration method-Exaquantum Source
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Install PI Server software on desktop PC
Configure PI-EQ COM Connector to Exaquantum
Create points from test system with PI-EQ source
Set up PI to PI Interface between COM server and Migration
server
Run PItoPI interface to transfer data in time series order
between systems
Run for 3-month time slices, check for errors after each
archive
Periodic pause to restore Exaquantum history for transfer
P4 2.8GHz desktop, 512MB RAM
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Migration-Combine Systems
• Setup production HP Blade server
• Perform clean install of PI Software to final
path
• Stop PI on test system and change IP
Address
• Move test system Dat and Archives to new
server
• Copy across archives created on receiving
system
• Register copied archives on production
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Data Flows
Clients
Production Server
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Exaquantum Server
OGL LAN
Router
API Interface
Node
Receiving Server
COM Source Server
DCS LAN
CS-3000 Operator Stations
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Data Flows
Clients
Production Server
D
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m
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S
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v
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Exaquantum Server
OGL LAN
Router
API Interface
Node
Receiving Server
DCS LAN
CS-3000 Operator Stations
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Data Flows
Clients
Production Server
D
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m
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S
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v
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Exaquantum Server
OGL LAN
Router
API Interface
Node
DCS LAN
CS-3000 Operator Stations
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Data Flows
Clients
Production Server
Exaquantum Server
OGL LAN
Router
API Interface
Node
DCS LAN
CS-3000 Operator Stations
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Timing
• Set up test system mid march
• Proof of basic functionality and data transfer
by mid April
• Finalise hardware and software
requirements, SLA in May
• Port historical data in July
• Merge test system and historical archives
onto final server August
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Speed of transfer
• 1GB fixed archives created for each 3
month period
• Approximately 24 hours per 1 month of data
• Data compression turned off to speed up
• Data loaded in time series order to speed up
• Done in smaller time slices to catch errors
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Disc space requirements
• Historical raw data used up 123GB
• Transferred to new system used < 12GB
• Overestimated disc space needed
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System uses
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Long term trending
Automated email alerts
Concentrate inventory management
Remote monitoring and diagnosis
Production reporting
Throughput optimisation
Daily production review
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Control room monitoring
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Fast trending in DCS limited to 256 points per station
Multi-monitored PC in control room
Operator customised trend displays
Free up DCS stations for fault resolution
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Utilise History
• Review of operating parameters last 4 years
• Commissioning new equipment
– May 2007 startup of M1000 Isamill regrind
circuit
– August 2007 Batch processing of Reefton
Concentrate
– November 2007 startup of Outotec 300m3
flotation cells
• Autoclave throughput increase by 0.2tph
Sulphur
– 0.1tph Sulphur increase is worth $4,000/day
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Email alerts
• Automated notification of tank levels to
suppliers
• Critical equipment events to on call met
• Alerts on critical faults – mill bearings
• Out-of-box solution with existing OSI tools
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Concentrate inventory management
• Input movements through transport nodes into PI Tags
• Present summary status in Processbook
• EOM inventory tracking and scheduling from online
inventory
• Improved autoclave
scheduling from online
balance
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Remote Access
• Utilise existing IT Citrix Gateway or Remote
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Reefton Minesite Integration
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Concentrate shipped 800Km to Macraes site
Yokogawa CS3000 DCS onsite
Server license expanded to 5,000 tags
API node set up on site with OPC and OPC
A&E interface
• Data forwarded over WAN to Macraes server
• Clients connect to Macraes server with PB &
DL to access data
• Full view of operating trends to both sites and
remotely via Citrix gateway
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Reefton Minesite Integration
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Provides access to PI System
Utilise existing infrastructure and support
Shared data without synchronisation issues
Faster implementation for short term solution
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Going Forward
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Water management and consent monitoring
Link Caterpillar Minestar system
Improve user skills with client tools
Integrate plant reporting into PI
Deploy local server to Reefton
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Conclusions
• PI has significantly higher utilisation than
previous system
• Migrating data to PI allows full access to
history
– No need to maintain legacy Exaquantum server
– Faster access and less training required
– Exercise was much faster and easier than
expected
• Conversion simplified with a COM
Connector
• Provides basis for ongoing optimisation and
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