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Phelps Dodge Miami Inc.

Phelps Dodge Smelter Realized Cost Savings and Increased Revenues with OSIsoft’s PI System Vladimir Ushakov & Scott Voltura. Phelps Dodge Miami Inc. OSIsoft User Conference May 12-14, 2003 San Francisco. Communication Architecture. PI Server with RAID5. Application Servers.

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Phelps Dodge Miami Inc.

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  1. Phelps Dodge Smelter Realized Cost Savings and Increased Revenues with OSIsoft’s PI System Vladimir Ushakov & Scott Voltura Phelps Dodge Miami Inc. OSIsoft User Conference May 12-14, 2003 San Francisco

  2. Communication Architecture PI Server with RAID5 Application Servers Users PCs - PI clients with Win95 and W2K machines LAN Scanner 1. Gateway between LAN and Smelter (PLC) Data highway Scanner 3. Gateway between LAN and Honeywell DCS Local Control Network (LCN) Data highway Scanner 2. Gateway between LAN and Environmental Data highway LCN Data Highway Data Highway History Module

  3. Smelter General Schematic

  4. PI Server Considerations • We are a Microsoft shop. • PI was installed in 1999. • Collecting data for almost 5000 points. • Excel, Access and MS SQL as enterprise-wide data storing/manipulating engines. • Use PI-DataLink for Excel to display values for PI tags.

  5. PI Uses • Predictive/Preventative Maintenance. • Capital Expenditure Justifications. • Six Sigma Initiatives. • Failure Analysis. • Trouble Shooting. • Audit Operator’s Decision Making Rationale.

  6. Molten Metal Level to Control Opportunity to control demand/supply of primary product – copper.

  7. Rationale For Application • Operators used field input and applied a rule of thumb to determine necessary production levels. High losses incurred due to unbalanced demand/supply. With PI server: • Powerful data storing/retrieving tool. • Conveniently incorporates into MS Office • Data displayed in real time – reduced error in verbal communication and enhanced accuracy of demand/supply computations.

  8. Daily Plan

  9. GUI Design and Business Logic • Not overloaded with unnecessary features. • Based on the users’ input and suggestions. • Retrieves values for 26 main parameters used for planning purposes. • Business rules in Visual Basic, which allows communication to seamlessly flow among MS Office Applications.

  10. Demand/Supply Application

  11. Demand/Supply Application • Displays the status of product availability, predicts demand and then balances supply. • Communicates with PI server and Daily Plan to retrieve values for nearly 3 dozen critical parameters. • Posses a dynamic character due to nature of the business and requires a periodic fine-tuning activity.

  12. Financial Outcomes Year Generation Consumption Skims Percent Cu • 8,092 tons 776,692 tons 426 4.51 % 2002 4,713 tons 853,458 tons 407 2.57 % Delta 3,379 tons 76,766 tons 19 1.94 % 42 % 10 % 4% 43 % Savings $ 43,000 Revenue $ 200,000 Total $ 243,000

  13. Summary • These PI-DataLink applications enable operators to understand the current status of the product demand/supply. • Creates a tool to allow fine-tuning of the operating parameters which has reduced copper losses. Future plans: - To Integrate various MS Office features such as the automatic notification generation. - Improve GUI by migrating to Web applications.

  14. Thanks for Your Attention!

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