Phelps Dodge Smelter Realized Cost Savings and Increased Revenues with OSIsoft’s PI System Vladimir Ushakov & Scott Voltura Phelps Dodge Miami Inc. OSIsoft User Conference May 12-14, 2003 San Francisco

May 12-14, 2003 Slide 2 Communication Architecture LAN Data Highway LCN History Module PI Server with RAID5 Application Servers Users PCs - PI clients with Win95 and W2K machines Scanner 2. Gateway between LAN and Environmental Data highway Scanner 3. Gateway between LAN and Honeywell DCS Local Control Network (LCN) Data highway Scanner 1. Gateway between LAN and Smelter (PLC) Data highway Data Highway

May 12-14, 2003 Slide 3 Smelter General Schematic

May 12-14, 2003 Slide 4 PI Server Considerations We are a Microsoft shop. PI was installed in Collecting data for almost 5000 points. Excel, Access and MS SQL as enterprise-wide data storing/manipulating engines. Use PI-DataLink for Excel to display values for PI tags.

May 12-14, 2003 Slide 5 PI Uses Predictive/Preventative Maintenance. Capital Expenditure Justifications. Six Sigma Initiatives. Failure Analysis. Trouble Shooting. Audit Operator’s Decision Making Rationale.

May 12-14, 2003 Slide 6 Molten Metal Level to Control Opportunity to control demand/supply of primary product – copper.

May 12-14, 2003 Slide 7 Rationale For Application Operators used field input and applied a rule of thumb to determine necessary production levels. High losses incurred due to unbalanced demand/supply. With PI server: 1.Powerful data storing/retrieving tool. 2.Conveniently incorporates into MS Office 3.Data displayed in real time – reduced error in verbal communication and enhanced accuracy of demand/supply computations.

May 12-14, 2003 Slide 8 Daily Plan

May 12-14, 2003 Slide 9 GUI Design and Business Logic Not overloaded with unnecessary features. Based on the users’ input and suggestions. Retrieves values for 26 main parameters used for planning purposes. Business rules in Visual Basic, which allows communication to seamlessly flow among MS Office Applications.

May 12-14, 2003 Slide 10 Demand/Supply Application

May 12-14, 2003 Slide 11 Demand/Supply Application Displays the status of product availability, predicts demand and then balances supply. Communicates with PI server and Daily Plan to retrieve values for nearly 3 dozen critical parameters. Posses a dynamic character due to nature of the business and requires a periodic fine- tuning activity.

May 12-14, 2003 Slide 12 YearGenerationConsumptionSkimsPercent Cu 20018,092 tons776,692 tons % 20024,713 tons853,458 tons % Delta3,379 tons76,766 tons % 42 %10 %4%43 % Savings$ 43,000 Revenue$ 200,000 Total$ 243,000 Financial Outcomes

May 12-14, 2003 Slide 13 Summary These PI-DataLink applications enable operators to understand the current status of the product demand/supply. Creates a tool to allow fine-tuning of the operating parameters which has reduced copper losses. Future plans: - To Integrate various MS Office features such as the automatic notification generation. - Improve GUI by migrating to Web applications.

May 12-14, 2003 Slide 14 Thanks for Your Attention!

May 12-14, 2003 Slide 15