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In 2018, Buenaventura Mining Company assigned PIPER Solutions to perform the analysis, design and implementation of the AVEVA PI System at its main mining units in Peru, the scope included the mining operations of Uchucchacua, Tambomayo, Orcopampa, Coimolache and the Rio Seco plant.

PIPER's specialized engineers carried out the information survey

Operational and requirements identifying all the data sources of the Mine, Plant, Maintenance and Laboratory operations of each of the mining units. In this first survey, control systems of different brands, isolated and non-historized signals and the different communication protocols for each data source were identified, among which we can mention: Siemens (Wincc, Pcs7), Schneider (PME), Wonderware, ABB, Rockwell, PLC, SQL, Kepserver, among the most important ones.

The architecture of AVEVA PI System was designed by our team of specialists

considering the communication requirements of Mines Buenaventura for each of the units. The integration of all identified information sources and the type of OSIsoft interface used in each of them was considered. For example, Modbus type interfaces to AVEVA PI System for the Mine area, OPC DA type interfaces for the Plant area, RDBMS type interface to PI for the Laboratory and Energy area.
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The main AVEVA PI System servers such as PI Data Archive, PI Asset framework and PI Vision were installed and configured

In each of the mining units in order to have faster responses and reduce information latency, considering hardware resources for the storage of operational information for a period of 5 years. A total of 28 interfaces (API Nodes) required to collect information from data sources were configured. For the management of plant assets, hierarchical models were developed in PI AF following the structure defined in the SAP PM system, in addition to calculations using PI Analytics and notifications to users of critical signals using PI Notifications..

Solutions for each Challenge

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Mine

Challenges

To have visualization of mine operations signals that allows monitoring of ore production from any location. Previously, visualization was only possible in the Control Room on an HMI interface that connected to the PLC and was limited to signals. Automatic production calculations. Previously, counting was done manually on paper.

Solutions

  • Calculations were developed for production in subway mines such as the amount of mineral extraction from the shafts, counting the Skips x Hour, as well as monitoring signals from hoisting winches showing indicators of bearing temperature, lubrication motors, reset status, Horometers, etc. to equipment that were isolated without information records for many years.

  • In the visualization part, Dashboards were built in PI Vision showing in real time the location of the Skips, the amount of ore and sterile material produced, the energy and hourmeters of the equipment. Visualizing the processes in real time from anywhere through multiple devices.

  • Operations reports were made in PI Datalink for main ore extraction and hourly skips reports.

  • To have visualization of mine operations signals that allows monitoring of ore production from any location. Previously, visualization was only possible in the Control Room on an HMI interface that connected to the PLC and was limited to signals. Automatic production calculations. Previously, counting was done manually on paper.

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On Plant

Challenges

Relate the plant signals with the tree signals in PI AF to handle the same standard with the SAP PM structure. Development of automatic reporting in PI DataLink of plant production, combining operational signals and laws. Design of PI Vision displays for operational monitoring of plant circuits, development of calculations and notifications to obtain plant production.

Solutions

  • Mapped crushing, milling, flotation, tailings and flotation process signals into the HF model and performed tonnage production calculations by shift and daily totals. Developed PI Datalink report of the Daily Report, obtaining tonnage and grades from the AVEVA PI System. PI Vision displays were designed for the visualization of the crushing, grinding, flotation and Tailings circuit.

  • The displays were made to monitor bearing temperature, lubrication motors, status of each motor, hours of operation, and visualization of different Operating signals of the Assets.

  • The integration of the main ION energy meters to the AVEVA PI System was performed and then proceeded with the inclusion in the PI AF hierarchical model.

  • The creation and development of a General Dashboard for Plant Operations was carried out in order to visualize integrated information on mine production, laboratory grades, energy, and their respective trends.

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Lima headquarters

Challenges

Another important requirement was to have the relevant operational information of each of the units centralized in a Corporate Server located in the city of Lima, to generate metallurgical balances, for which the implementation of PI to PI interfaces was defined, allowing the sending of production information from the plants to the Corporate PI Server and from there, the grade information to each of the units, considering that the application used by Mines Buenaventura to store its grades is located in the Lima network.

Solutions

  • The main operational signals were integrated into the infrastructure of the Corporate PI Server in Lima, which were used to perform the metallurgical balance.

  • An HTML-like interface was implemented in the corporate PI Server to allow communication with the main metal price web pages. The AVEVA PI System also helped to correct automated signals that showed bad data and those that were not in use.

  • Finally, AVEVA PI System training was conducted in each of the mining units, with courses on visualization tools, PI DataLink and PI Vision, so that the users themselves can continue to develop the PI Sytem.

  • In this way, Buenaventura Mining Company began to join the world of digitalization, monitoring its operations in real time for better decision making.

Río Seco Results

Orcopampa Results

Tambomayo Results

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