Real Time Information – Currency of the New Decade © Copyright 2011, OSIsoft LLC. All rights Reserved.

Making PI Mopani’s key tool in

Production and Management

Jane Mulenshi Munyao Plant Metallurgist & PI System Administrator Mopani Copper Mines Plc 24th February 2011

MOPANI

Regional Seminar Series Johannesburg, South Africa

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• Industry

– Mining

• Our Business

– Copper and Cobalt metals

• Organization / Sites

– Country: Zambia

– Province: Copperbelt

– Town: Kitwe & Mufulira

– Sites: Nkana in Kitwe (Underground Mine,

Concentrator & Cobalt Plant)

Mufulira (Underground Mine,

Concentrator, Smelter & Refinery)

About “Mopani Copper Mines Plc” MOPANI

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Mufulira Smelter Upgrade Project (MSUP) Phase 1

• Commissioned in September 2006 - Isasmelt Furnace, Matte Settling

Electric Furnace (MSEF), Sulphuric Acid Plant & Oxygen Plant

• Plant Wide Process Control System (Yokogawa CENTUM CS 3000 System)

• OSIsoft PI System

MOPANI

Introduction of PI at Mopani

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Challenges before PI introduction

• No easy way for production staff to monitor the plant

• No easy way for maintenance staff to monitor critical instruments

• No easy way for management staff to monitor the plant overall

performance & aggregate data into meaningful business information

• Manually entered log sheets were the only source of plant

information

• Excel was the analysis tool of choice leading to data silos and

multiple versions of the truth

• How do we monitor the highly automated new plants (Isasmelt,

Oxygen & Acid Plants)?

MOPANI

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Solution

• PI System implementation

- to monitor the performance of the new plants away from the control

rooms

- to have one version of the truth about plant data

- to enhance continuous process improvement

- to reduce operational costs

MOPANI

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OSIsoft Software and Services Used

• PI Server (6000 Tags)

– PI Interface Configuration Utility

• PI-Interface Status Utility

• PI OPC DA Interfaces (Server License - 7 OPC Interface Nodes)

– PI_OPCClient

– PI Interface Configuration Utility

– PI-OPC Tag Configuration Utility

• PI Clients

– PI ProcessBook

– PI DataLink

– PI ActiveView

– PI System Management Tools

• Software Reliance Program (SRP) Services

MOPANI

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`

PI System Architecture MOPANI

PI OPC

Interface

Nodes

PI ProcessBook

PI DataLink

Data Source

(DCS)

Data Source

(PLCs)

`

PI Server

opcint2

opcint2a

opcint1 opcint3 opcint4 opcint5

opcint5a

opcint5b

opcint6 opcint7

PI ActiveView

PI Clients

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Making PI the key tool MOPANI

• September 2006 to October 2007

– Limited PI usage

• April – June 2008

– PI client training

• July 2008 to-date

– PI ProcessBook displays developed

– PI DataLink used to analyze PI data

– PI ActiveView usage introduced

– PI OPC Interface Nodes increased (Server License)

– PI Server upgraded from 5000 to 6000 tags

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PI ProcessBooks MOPANI

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PI ProcessBook Displays MOPANI

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PI ProcessBook Trend Displays MOPANI

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PI ActiveView Displays MOPANI

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PI DataLink MOPANI

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Case Study 1

Improved Process Monitoring MOPANI

DAY SHIFT

Unit Activity 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00

No. 2 Converter Matte in (V1)

Slag Blow (min)

Cold Standby Cu Blow (min)

Blister Out (V1)

No. 3 Converter Matte in (V1)

Slag Blow (min)

Empty Cu Blow (min) Hot Standby

Blister Out (V1)

No. 4 Converter Matte in (V1) 4 3

Slag Blow (min) 0.5

Reaming Cu Blow (min) Blow No. 80

Blister Out (V1)

No. 5 Converter Matte in (V1) 4 3

Slag Blow (min) 0.5

Copper Blow Cu Blow (min) Blow No. 132 Blow No. 133

Blister Out (V1) 4

No. 6 Converter Matte in (V1) 4 3

Slag Blow (min)

Copper Blow Cu Blow (min) Blow No. 189 Blow No. 190

Blister Out (V1) 4

80POTSAVAIL.PV

C:C2_AIRFLOW.AI_IN_EU

-3649

Nm3/hr

C:C3_AIRFLOW.AI_IN_EU

5398

Nm3/hr

C:C4_AIRFLOW.AI_IN_EU

43239

Nm3/hr

C:C5_AIRFLOW.AI_IN_EU

113

Nm3/hr

C:C6_AIRFLOW.AI_IN_EU

75

Nm3/hr

C:BLOWER_PRESSURE.AI_IN_EU

C:CP_PRESSURE.AI_IN_EU

12:00 11:00 8:00 7:00

14-Feb-11 12:26:15CF BLAST AIR MONITOR

-300000

-250000

-200000

-150000

-100000

-50000

0

50000

100000

-300000

150000

-200000

200000

-150000

250000

-100000

325000

14-Feb-11 07:00:00

-3649

5492

132

45327

5943

Process Plan

Status at 07:00hrs

Plan = Actual

Slightly earlier

than plan

Actual Process

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Case Study 2

Reliable Source of Data in Real Time MOPANI

Only source of data for this process before PI 80POTSAVAIL.PV

C:C2_AIRFLOW.AI_IN_EU

C:C3_AIRFLOW.AI_IN_EU

C:C4_AIRFLOW.AI_IN_EU

132

Nm3/hr

C:C5_AIRFLOW.AI_IN_EU

C:C6_AIRFLOW.AI_IN_EU

C:BLOWER_PRESSURE.AI_IN_EU

1.17

bar

C:CP_PRESSURE.AI_IN_EU

9:00 7:00 5:00 3:00 22:00 20:00 18:00 16:00

07-Feb-11 10:00:00CF BLAST AIR MONITOR

-200000

-150000

-100000

-50000

0

50000

100000

150000

200000

-3

20

07-Feb-11 02:16:00

132

1.14

06-Feb-11 17:16:00

5360

1.15

07-Feb-11 09:21:00

5379

1.17

Blower Air Pressure Trend

Total Inter-blow Time

Total Blowing &

Delays Time

Air Flow Trend

CONVERTER SLAG BLOW COPPER BLOW BLOW SUM AVG IN-STACK OUT-OF-STACK

NO. BLOW No. start/end START STOP TIME AIR FLOW AIR FLOW TIME (hrs) TIME (hrs)

4 64

2:16

9:21 7:05

214005.59 37114.38 5.55 1.54

PI-Datalink

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Benefits

• Improved process monitoring

• Ability to monitor performance on a daily basis

• One reliable source of data in real time and

archived

• Less time spent in process analysis due to readily

available process data and statistical analysis tools

• Trouble-shooting time reduced

• Management has accurate & timely information

about process areas needing their attention hence

timely business decisions are being made too

MOPANI

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Future PI Plans

• Nkana Site

– Nkana Concentrator

– Leach Plant

– Mindola Compressor House

– Copper Tank House

– Cobalt Tank House

– South Ore Body (SOB) Compressors

– Winders

– Power monitoring

• Mufulira Site

– Refinery SX Plants

– Refinery Tank Houses

– Power Monitoring

– Winders

MOPANI

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MOPANI

Making PI Mopani’s key tool in production and

management

QUESTIONS

THANK YOU!!!

Mufulira Smelter Team

Thank you

© Copyright 2011 OSIsoft, LLC.

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