Phelps Dodge Miami Inc.

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Phelps Dodge Miami Inc.
Phelps Dodge Smelter Realized Cost Savings and
Increased Revenues with OSIsofts PI
System Vladimir Ushakov Scott Voltura

• OSIsoft User Conference
• May 12-14, 2003
• San Francisco

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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
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Smelter General Schematic

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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.

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PI Uses

• Predictive/Preventative Maintenance.
• Capital Expenditure Justifications.
• Six Sigma Initiatives.
• Failure Analysis.
• Trouble Shooting.
• Audit Operators Decision Making Rationale.

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Molten Metal Level to Control

• Opportunity to control demand/supply of primary
  product copper.

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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.

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Daily Plan
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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.

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Demand/Supply Application
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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.

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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

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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.

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• Thanks for Your Attention!

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