FREEPORT-M

FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Implementation of Aspentech
Web21 and RBV

Rod Mill and Refinery Operations

Juan Sanchez
Kevin Scott
April 8, 2008

www.fcx.com
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Mine Process Overview

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Mine Process Overview

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Rod Mill Process Overview

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Final Rod Mill Product

Rod Mill Locations:
El Paso, TX
Miami, AZ
Norwich, CT
Chicago, IL

5/16” Copper Rod

7,400 lb packages
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Business Case

ƒ Enterprise Performance System was created to

increase operational efficiency across all Rod
Mills and improve product quality.
ƒ Gap analysis was done for each production
process
- Mapping of existing process flows
- Identify/define Key Performance Indicators (KPI)
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Business Case cont.

ƒ Implement Data driven system

- Create control plans for each area
- Develop “Cockpit Charts” to monitor KPI’s
- Shaft Furnace firing rates/CO levels
- Copper Temperature
- Cooling water flow/temp
- Emulsion flow/temp
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Challenges Encountered

ƒ Data Quality and Accessibility

- Manual collection of data
- Missing data points
- Frequency of collection
ƒ Visibility of Historical Data
- Current HMI display didn’t allow for historical
analysis.
- Cockpit Charts displayed only 1 day (hourly
readings)
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Current HMI
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Challenges Encountered

ƒ Ownership of process
- More work for Operators, less time to
complete work tasks
- Didn’t have buy in or see value in the added
activities
ƒ Tools used to collect data
- Interlinked Excel spreadsheets
- Security Issues, broken links, etc.
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

What problems do we want to

solve?
ƒ Enable Operators to focus on primary job
function vs. data gathering
- Reduce error in data collection
ƒ Display KPI’s as both real time values and
operational trends
- Present the KPI’s in an easy to read layout
and relevant to each department/area
ƒ Create a standardized interface across all
rod mills.
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Aspentech Products installed

ƒ Aspen IP21
ƒ Aspen Web21
ƒ Aspen Operations Manager – Role Based
Visualization
ƒ Aspen Event Management
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Project Split into 3 groups

Standing up Servers
Integration with existing Maintaining IP21 Server
Infrastructure Adding tags

Process Owners
Graphic/Plot Creation
Building RBV Screens
Setting up Event Management
Maintaining RBV Roles
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Benefits of splitting up the project

ƒ Immediate buy in from the

Quality/Production groups
ƒ Only Critical Data displayed
ƒ Resource Management
ƒ Increased communication/teamwork for
non-Aspentech related projects
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Challenges of splitting up the

project
ƒ Resource availability
- Resources pulled away to work on other
projects
- Differing priorities
ƒ Communication key to success between
the three groups
ƒ Bigger learning curve for
Quality/Production group
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Initial Project Scope

ƒ First Prototype in El Paso Rod Mill

- IP21 Server – local
- Web21 Server – Located at Phoenix Corporate
IS
ƒ Centralized Server per Corporate
Standards
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Prototype Setup
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Issues with Prototype

ƒ Network Latency between local IP21

server and Web21 server in PHX
ƒ Security Issues between Business vs.
Process Control zones within FMI’s
infrastructure
ƒ The use of Virtual servers
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Final Configuration

Phoenix
Corporate Center
Sharepoint server for Document
Libraries

El Paso Rod Mill Norwich Rod Mill

IP 21 Server IP 21 Server
Sharepoint/Web21 Server Sharepoint/Web21 Server
Client PC’s Client PC’s’

Miami Rod Mill Chicago Rod Mill

IP 21 Server IP 21 Server
Sharepoint/Web21 Server Sharepoint/Web21 Server
Client PC’s Client PC’s
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Typical Excel KPI Spreadsheet

Inboard Block Temperature
Inboard Block Outboard Block Cooling Water Cooling Water
300

Temperature
Temperature Temperature Temperature Conductivity 290

Time Reading Time Reading Time Reading Time Reading 280

6:30 AM 0 6:30 AM 272 6:30 AM 108 6:30 AM 1661 270
7:30 AM 272 7:30 AM 275 7:30 AM 108 7:30 AM 1666
260
8:30 AM Down 8:30 AM Down 8:30 AM Down 8:30 AM Down
9:30 AM Cast 9:30 AM Cast 9:30 AM Cast 9:30 AM Cast 250
10:30 AM 280 10:30 AM 282 10:30 AM 104 10:30 AM 1786

AM

AM

9: M
10 A M

11 AM

12 AM

1: M

2: M
PM

4: M

5: M
PM

7: M

8: M

9: M
10 P M

11 PM

12 PM

1: M

2: M
AM

4: M

5: M
AM
P

A
A

A
11:30 AM 277 11:30 AM 275 11:30 AM 104 11:30 AM 1789

0
30

0
30

30

30

30

30

30

30

30

30

0
30

30

30

30

30
:3

:3

:3

:3

:3

:3
3

3
6:

7:

8:

3:

6:

3:
12:30 PM 275 12:30 PM 272 12:30 PM 108 12:30 PM 1824
1:30 PM 280 1:30 PM 280 1:30 PM 108 1:30 PM 1827 Time Of Reading
2:30 PM 277 2:30 PM 275 2:30 PM 111 2:30 PM 1832
3:30 PM 275 3:30 PM 272 3:30 PM 112 3:30 PM 1915 Outboard Block Temperature
4:30 PM 282 4:30 PM 280 4:30 PM 112 4:30 PM 1912
5:30 PM 280 5:30 PM 284 5:30 PM 112 5:30 PM 1917
6:30 PM 277 6:30 PM 278 6:30 PM 111 6:30 PM 2113 300

Temperature
7:30 PM 274 7:30 PM 275 7:30 PM 111 7:30 PM 2202 290
8:30 PM 288 8:30 PM 276 8:30 PM 111 8:30 PM 2189
280
9:30 PM 287 9:30 PM 289 9:30 PM 112 9:30 PM 2170
10:30 PM 281 10:30 PM 286 10:30 PM 112 10:30 PM 2164 270
11:30 PM 287 11:30 PM 284 11:30 PM 111 11:30 PM 2164 260
12:30 AM 284 12:30 AM 278 12:00 AM 111 12:30 AM 2164
250
1:30 AM 278 1:30 AM 277 1:30 AM 111 1:30 AM 2164
2:30 AM 2:30 AM 2:30 AM 2:30 AM

11 AM

12 AM

1: M

11 PM

12 PM

1: M
AM

8: M

9: M
10 AM

2: M
PM

4: M

5: M
PM

7: M

8: M

9: M
10 PM

2: M

3: M

4: M
AM

AM
A

A
3:30 AM 3:30 AM 3:30 AM 3:30 AM

0
30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30
:3

:3

:3

:3

:3

:3
6:

7:

3:

6:

5:
4:30 AM 4:30 AM 4:30 AM 4:30 AM
Time Of Reading
5:30 AM 5:30 AM 5:30 AM 5:30 AM

Cooling Water Temperature Cooling Water Conductivity

120 2600
2400
Temperature

Conductivity

115 2200
2000
110
1800
105 1600
1400
100 1200
AM

AM

AM

PM

PM

PM

PM

PM

PM

AM

AM

AM

AM

AM

AM

PM

PM

PM

PM

PM

PM

AM

AM

AM
0

0
:3

:3

:3

:0

:3

:3

:3

:3
3

3
6:

8:

2:

4:

6:

8:

2:

4:

6:

8:

2:

4:

6:

8:

2:

4:
10

12

10

12

10

12

10

12
Time Of Reading Time Of Reading
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Management Screen
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Furnace Operators RBV Screen

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Furnace Operators RBV Screen

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Caster Operator’s RBV Screen

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Caster Operator’s RBV Screen

 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Role Based Visualization

ƒ Originally started with 7 roles

ƒ Quickly grew to 26 roles
ƒ Scaled back down to 10 roles
- Each role can see entire plant
ƒ The roles were scaled back to address the
need to view multiple screens as well as to
address the escalating alarm scenarios of
Event Management.
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Lessons Learned

ƒ Need to have a SharePoint server at each

Rod Mill to address network latency
ƒ Microsoft virtual server vs. VM ware
ƒ Resource commitment for entire project
life
ƒ Commitment from Management to use
data in day to day business
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Next Steps

ƒ Increase Event Management utilization

ƒ Integration Infrastructure (Tibco bus)
- Tie in to financial systems
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Business Value

ƒ Standardized HMI across the four Rod Plants

ƒ Increased visibility of process at all levels
ƒ Operator’s freed from doing hourly checks and
filling out data manually
ƒ Process is now looked upon using trend or
historical data vs. points in time
ƒ Environmental Compliance
ƒ Increased flexibility to deploy new information
across all levels of the organization
 FREEPORT-M
FREEPORT-MCCM
MOOR AN COPPER
RAN COPPER &
& GOLD
GOLD INC.
INC.

Questions?