Transcription
The role of PI System in the machinery efficiency improvement program inJSWJacek Kwaśnica#PIWorld 2019 OSIsoft, LLC1
Agenda About JSW Mining core principles JSW challenges CTDS Central Technology Data Server Implementation details Future with PI Summary#PIWorld 2019 OSIsoft, LLC2
Jastrzębska Spółka Węglowa – Capital GroupLocated in the industrial heartland of Europe 4 coal mines 3 coking plantsUpper eZdrójCoking coal focusedZabrzePrzyjaźńBudryk headquartered in Jastrzębie-Zdrój, PolandPniówekBorynia/ZofiówkaKatowiceCoke PlantCoal MineHeadquarters Holds 14% of the global coke trade marketLong mine life 30–40 years expected life of minesSolid total resources and reserves Total resources of approx. 5.497 billion tonnes Reserves of 0.952 billion tonnes#PIWorld 2019 OSIsoft, LLC3
Advanced Data Analytics CenterJSW Program:Improving mining efficiency Reduction unplanned downtimesImproving uptime in a challengingoperational environment#PIWorld 2019 OSIsoft, LLC4
Mining core principles Mining method – underground longwall miningLongwall machines Shearer Armored Face Conveyer (AFC) Stage Loader Roof Supports Conveyor beltStageLoader Longwall exploitation for several months Difficult wireless communications, interrupteddata transmissionsAFCShearer#PIWorld 2019 OSIsoft, LLC5
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Mining core principles Production processes follow the coal Workplaces appear and disappear1I20171 VI20171I20181 VI20181I20191 VI2019#PIWorld 2019 OSIsoft, LLC8
Mine spatial scheme1I2017#PIWorld 2019 OSIsoft, LLC9
Mine spatial scheme1 VI2017#PIWorld 2019 OSIsoft, LLC10
Mine spatial scheme1I2018#PIWorld 2019 OSIsoft, LLC11
Mine spatial scheme1 VI2018#PIWorld 2019 OSIsoft, LLC12
Mine spatial scheme1I2019#PIWorld 2019 OSIsoft, LLC13
Mine spatial scheme1 VI2019#PIWorld 2019 OSIsoft, LLC14
JSW challengesJSW typical mineBusiness IntelligenceSCADA 1Longwall 1SCADA 2Longwall 2Dispatch SystemLongwall 3?ERP/CMMSDrift 1#PIWorld 2019 OSIsoft, LLC15
Solution - Central Technology Data ServerBusiness IntelligenceInterfaces Modbus OPC (UA) RDBMS UFLCMMSAnalyticsLongwall Reporting SystemCTDSUndergroundfiber opticnetworkB-Z-JBudrykPniówekK-S#PIWorld 2019 OSIsoft, LLC16
Transforming mine data into practical informationCase 1.AF structure reflecting mine topologyCase 2.Logical relations between machinesCase 3.Rollup calculations – mine, corporate KPI’sCase 4.Automatic downtimes recognitionCase 5.Haulage system optimization#PIWorld 2019 OSIsoft, LLC17
Case 1 - AF structure reflecting mine topologyMinesShearerMachinetechnicalparametersfrom CMMSAFC1100011Conveyor beltLongwallShearerStage loaderAFCRoadheaderMachineworkplacehistoryLongwall system (LS)#PIWorld 2019 OSIsoft, LLC18
Case 2 - Logical relations between machinesAF analysisMachinerunning/stoppedMachine timeusageComplexityLongwall systemrunning/stoppedLongwallsystem timeusageLongwallsystem shifttime usage#PIWorld 2019 OSIsoft, LLC19
Case 3 - Rollup calculations – mine, corporate KPI’sWorking time usage (average for all longwall systems) within one mineLongwalls#PIWorld 2019 OSIsoft, LLC20
Case 3 - Rollup calculations – mine, corporate KPI’sWorking time usage (average for all longwall systems)Mines within all mines#PIWorld 2019 OSIsoft, LLC21
Case 4 - Automatic downtimes recognitionLS downtimes go to CMMSRed trend –LS downtimeslonger then 30minEvent framesgeneratedEvent log inCMMS(integrationexample)#PIWorld 2019 OSIsoft, LLC22
Case 5 - Haulage system optimizationEvents based on relations between machines1’st Conveyor beltLongwall system#PIWorld 2019 OSIsoft, LLC23
Case 5 - Haulage system optimizationEvents based on relations between machinesEvent 1: Overloading 1’st conveyor beltBO reports for mine staffEvent 2: Running empty on 1’st conveyor belt#PIWorld 2019 OSIsoft, LLC24
CTDS – management dashboard#PIWorld 2019 OSIsoft, LLC25
CTDS – operational level dashboards#PIWorld 2019 OSIsoft, LLC26
CTDS – integration details Downtimes from PI to CMMSAF analyze PI Point EF PI OLEDB ENT View MS SQL Linked server PentahoIntegration Process Oracle View (CMMS) Technical machine parameters from CMMS to PIOracle View (CMMS) Linked Table in AF Table Lookup in AF Plant calendar from ERP to PIOracle View (ERP) PI RDBMS Interface PI PointAggregated (by shifts) machines work timesPI OLEDB ENT View Linked Table in AF Table Lookup in AF Machine Work Times from PI to SAP Business ObjectsPI SQL RTQP View Pentaho Integration Process SAP Business ObjectsDatabase#PIWorld 2019 OSIsoft, LLC27
Future with PI New use cases implementation Entire haulage system Ventilation, drainage processes Extending monitoring to other areas Coal Processing Plant Cocking Plant Step towards Predictive Maintenance (PdM)#PIWorld 2019 OSIsoft, LLC28
Mining efficiency improvementCHALLENGES Increase working timeat the coal faceSOLUTION AF structure RT Analysis AF Event Frames PI Vision dashboards BENEFITS Integration with CMSS PI SQL RTQP Improved OEE for mine machinesIncreased awareness of process issues(about 3 times more downtimes registered andannotated)New options for haulage optimizationsShared and transparent technical dataReduced report preparation time(preparation of monthly uptime report was reducedfrom 1h to 1m)“Our Central Technology Data Server has gave us greater awareness of undergroundcoal mine processes despite their high variability#PIWorld 2019 OSIsoft, LLC29
The role of PI System in the machinery efficiencyimprovement program in JSW Jacek Kwaśnica PI System coordinator JSW S.A. jkwasnica@jsw.pl#PIWorld 2019 OSIsoft, LLC30
Questions?Please remember to Complete Survey!Please wait forthe microphoneState yourname & companyNavigate to this session inmobile agenda for surveyDOWNLOADTHE MOBILEAPP#PIWorld 2019 OSIsoft, LLC31
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CTDS -integration details Downtimes from PI to CMMS AF analyze PI Point EF PI OLEDB ENT View MS SQL Linked server Pentaho Integration Process Oracle View (CMMS) Technical machine parameters from CMMS to PI Oracle View (CMMS) Linked Table in AF Table Lookup in AF Plant calendar from ERP to PI
