Customer StoriesMining, Metals and Minerals

IAMGOLD Rosebel Gold Mines

By 8th November 2016 No Comments

Industry: Mining

Suriname gold mine benefits from SA knowhow and Wonderware solutions

Goals

  • Commission Wonderware Information Server
  • Automated publishing of existing reports
  • Manipulate data to provide value-added reports

Solutions and Products

  • Wonderware Information Server
  • Active Factory
  • Wonderware Historian

Challenges

  • Setup of WIS through IT security to make information available enterprise wide
  • Integrate 3rd party software to produce meaningful reports
  • Using SQL and visual studio to present these reports to various department heads

Results

  • Accurate reporting with reports available in the format of those who request them
  • End-user-definable reports requiring no outside help
  • Historical and live information as well as process graphics are available to IAMGOLD’s Toronto-based engineers for process supervision and optimisation
  • Engineering and mill supervision apprised of downtimes and their reasons
  • Metallurgical teams can spot problem areas at a glance
  • Motor performance available to planners for predictive maintenance
  • All information is based on aggregated real-time data rather than snapshot values
  • The analysis of results highlighted many previous reporting errors
  • Elimination of Excel reports

Suriname, South America – With the price of gold pinned by international markets, one of the avenues open to greater profitability for gold mining companies is through improved mining and beneficiation processes and greater operational efficiency – none of which can be done without accurate, real-time information.

Background

Rosebel is an open pit mine which feeds the extraction process shown in figure 1. The automation system already in place before this project was started included the Wonderware System Platform, InTouch HMI, Information Server and Historian all of which were implemented by a Canadian system integrator.

“IAMGOLD heard of our successful implementations of information solutions for mining companies using Wonderware products and commissioned us to implement a fully-automated reporting solution for Rosebel,” says André Vuilleumier, MD of SA system integrator Systems Anywhere. “In addition, IAMGOLD wanted a solution that would monitor and manage downtime.”

In addition to these primary objectives, IAMGOLD made it clear that the mine must have complete control over the design and generation of reports without outside help and, according to Vuillemier, this would be greatly facilitated by the underlying ArchestrA technology which makes the functionality of the system easy to configure by instrumentation personnel rather than programmers once an infrastructure and templates have been implemented.

Implementation

“As shown in figure 1, the Wonderware Historian is the main data collector for the reporting,” says Vuilleumier. “It features extremely fast writing speeds capable of keeping up with the fastest events. The data warehouse is an engine that aggregates the data from the Historian at cyclic intervals prior to reporting because the amount of raw data from a sizable plant is unmanageable unless it is collated and contextualised in a meaningful way. For example, bearing temperature is only meaningful when the motor is running otherwise we’re simply aggregating ambient temperature. After aggregation, the information is available to virtually any application from production reporting to maintenance and ERP platforms.”

The data warehouse uses reference, definition and calculated tables which are interlinked using unique IDs that are used to reference stored procedures. A job executes specific stored procedures at predetermined intervals according to the calculation type in order to update the calculated tables. Stored procedures use the Transact-SQL language for generating code that will extract/modify data from tables specified by the functionality of the stored procedure. All aggregated values are stored in the results table and most of the queries use this table as reference for result sets.

“Some of the challenges we faced were the integration of the various existing reporting structures as well as understanding the business and plant models for report generation and distribution. Other challenges included cleaning up the Galaxy repository and improving the information flow to users for business analysis once reports had been generated,” says Vuillemier.

Reporting

“The result of what we’ve done here is nothing new,” says Vuilleumier. “After all, everyone in the industry needs specific reports to better manage their production and a lot depends on how those reports were generated and what basic data they used. Many Wonderware clients are pumping data into the Historian but how can they make informed business decisions based on what’s in there? That’s why products like as FLOW and Dream Reports are becoming increasingly popular. “With ArchestrA’s tool kit, we were able to design and build some of the objects that were used in the templates devised to meet Rosebel’s requirements.

The result is that the right people are made aware of the KPIs of interest to them as and when they occur and in a very specific way. For example, if there’s an operational issue like a power failure, the plant shouldn’t be penalised for decreased production. So, for the downtime reporting, the user has the choice of selecting whether downtimes were caused by an operational, maintenance or any other cause. Every plant is the same in needing to know about efficiency and profitability yet every plant is different with regards to what information it needs to sustain those goals. Providing customised yet integrated reports using the ArchestrA toolkit is one way.”

The implementation of the system allows Rosebel to further develop the downtime reports in house to be used for the accurate analysis of downtime causes. Now that the system provides remote access to users throughout IAMGOLD, it has seen a notable increase in use for operational issues at the mill processing plant during its first four months of operation.

Benefits

  • Accurate reporting with reports available on request and aggregated to the dates specified by those who need it where, when and how they need it
  • End-user-definable reports requiring no outside help
  • Engineers throughout IAMGOLD can now use historical and live information in their predictive models resulting in well-informed decisions regarding expansion and process streamlining
  • Engineering and mill supervision are aware of downtime allocations as well as the reasons for these stoppages
  • KPI and runtime statistics are available to metallurgical teams who can spot problem areas at a glance
  • Motor running hours and number of start / stops available to planners for predictive maintenance
  • Process analysis and reporting are based on aggregated real-time data rather than snapshot values
  • The analysis of results highlighted many previous reporting errors
  • Elimination of Excel reports
  • Process graphics available over the whole domain including IAMGOLD’s head office in Toronto, Canada