Ignition Enables Data Collection, Analysis, and Much More

6 min video  /  2 minute read

Project Overview

The plant needed to extract information from its Siemens PCS7 redundant systems. It also needed to use that information to obtain important data such as key performance indicators (KPIs), production indices availability, rate of consumption of electric power, and metallurgical tracking. This is all to monitor the status of the plant for data process optimization.

Ignition is being used as an Industrial Information System and allows Constancia to obtain KPIs for daily production, maintenance, downtime, and equipment operation. It helps the production team to quickly find problems that prevent it from achieving optimal production.

The system also allows users to perform detailed analysis and provide solutions as well as to schedule the production to compare it with actual values.

Given the integrated and historical information with the Ignition Constancia system, it is passed to the stage of development of various reports and different analysis, monitoring, and trending screens. Reports are made of production, maintenance, energy consumption and other factors.

The most important reports are the daily report on production, maintenance and monitoring of stops related to the main plant machinery such as mills, operations, crusher, and monitoring data of metallurgical and electrical areas.

Also, we work in a mobile system that shares the same tags that were extracted from the PCS7 Siemens system. This is a great tool for a staff that is distributed throughout the plant performing diagnostics on different equipment.

The average number of daily connected clients is about 50 people who use the system for monitoring data and the mobile system for different areas.

One aspect that is special about this project is the integration of production data, monitoring stops, data monitoring electricity, compared to major plant equipment, as facilitated to obtain important data such as the rate of equipment availability, energy consumption index, KPI daily, weekly and monthly production, metallurgical data — all of which is used for planning the day-to-day production.

All areas at Constancia (Production, Control, Maintenance, Metallurgy, IT) are now working together based on Ignition. The mine uses the data as a pillar of its production. The data helps decision-makers optimize production, consumption, and availability.

Project Information

Created By:   FEPROM Solutions

FEPROM Solutions is an engineering company specializing in instrumentation, automation and low/medium voltage systems design and implementation for mining plants. FEPROM started operations in 2009, and since then has participated in some of the largest and most important mining projects in the world. We have highly trained engineers on staff and our business is global. Our mission is to provide the most reliable and efficient control systems possible. Our approach is an integrated team effort based on a core of engineers with years of experience in instrumentation, automation, DCS, low/medium voltage systems and mining processes. We enhance this engineering core with full-time metallurgists and IT professionals. The synergies of this integrated team approach have resulted in a culture that produces quick reactions and creative solutions to complex problems.

Website: www.feproms.com

Project For:   Minera Constancia - Hudbay

Constancia is a copper mine located in Peruvian territory, wholly owned by HudBay, obtained through the acquisition of Norsemont in 2011. It is located in the province of Chumbivilcas in southern Peru and is formed by deposits of Constancia and Pampacancha. On August 8, 2012, the Board of Hudbay approved an investment of $1.5 billion to finance the development and construction of its Constancia project in Peru. In the third quarter of 2013, with substantial progress of the detail engineering, the Board approved a revised capital cost estimate for the project of $1.7 billion. Production began as expected in the fourth quarter of 2014 and achieved commercial production on April 30, 2015.

Posted on September 1, 2016