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Challenges, Opportunities and Strategies for Integrating IIoT
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OSIsoft Brings PI System to Amazon Web Services
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In 2016, Goldcorp launched an ambitious plan, dubbed “20/20/20,” that aims to achieve a 20% increase in gold production, a 20% increase in gold reserves, and a 20% reduction in all-in sustaining costs. As part of that plan, the company initiated a PI System pilot project at its mine in Peñasquito, Mexico, to provide operators with real-time data and deliver dynamic performance targets to enhance metal recovery from the feed moving through the plant. In its first year, the project achieved a rapid return on investment, boosting the recovery rate of metals and effectively adding the equivalent of four to five days of additional production at Peñasquito.
A typical offshore deep-water rig may be two or three hours by helicopter from land, making it one of the most hostile and logistically challenging environments on the planet. Deep-water rigs cannot be moored, and must be kept in place with huge thrusters to counteract the pressure of the wind and waves. The rigs are loaded with large, expensive and potentially dangerous equipment from many different manufacturers, each with its own proprietary data interface. Satellite communication with the mainland can be spotty, and bandwidth for exchanging data is a precious resource. Transocean operates a fleet of 47 drilling rigs worldwide, each with up to 250 workers living and working on rig at any given time. As a result, they turned to OSIsoft's PI System to help improve well performance, enhance worker safety, enable greater automation, and move toward condition-based maintenance of critical equipment.
Fuel burn rate, wear and tear on the hull, vibration, equipment maintenance, shifting weather conditions, different possible routes: all of these factors, and more, combine to steer the path and the pace of a ship through the sea. Most captains navigate a sea of decisions board ship with the help of expertise and old-fashioned intuition. But there is an increasingly important role for data to play, too. With the help of OSIsoft's PI System, the British defense firm BAE Systems is proving that taking data analysis and machine learning to sea can yield dramatic savings on shipping costs.
In 1837, Australian Gas Light Energy (AGL) was founded in Sydney, Australia. At the time, Sydney was a small colonial outpost with less than 35,000 people, and “grid management” consisted of operating a few gas lamps. Today, AGL manages one third of the energy of Australia's eastern seaboard, where most of the nation's population lives. Acquistions and renewable adoption have been accelerating growth. In 2012, when David Bartolo, Head of Asset Performance, joined AGL, they had grown from 300 MW in 2005 to 5500 MW and were looking to further expand to 9000 MW. However, growth came at a price. “We were completely data blind,” said Bartolo at PI World San Francisco in 2018. “I had built a central asset management team. They were really clever people with years and years of experience, and they couldn't see a single piece of real-time data centrally… I had to ask one of the sites to print off a trend every ten seconds and send me the screenshots so I could understand what happened during an overflow incident. It doesn't get worse than this,” he said.
Something needed to change at Aurelia Metals. Gold recovery rates were less than 75 percent and throughput low at the end of the fourth quarter f 2015. If Aurelia was going to survive, its Perth processing plant needed to increase its recovery rate to 85 percent. It also needed to increase cash flow and capital. When Peter Smith, Metallurgy Superintendent at Aurelia Metals, started his role on February 1, 2016, he had no idea of the task at hand. Two days later, when he was briefed on the state of the plant, he knew one thing: he needed the PI System to remove manual processes and gain the necessary visibility to implement process control. By mid-March, the PI System was up and running, recovery rates and throughput were improving, and Aurelia's stock was rising.