1. Dave Hunter Group Leader - Metallurgical Accounts, QNI Pty Ltd Using PI for BSC Reporting at QNI

2. OSI PI Users Conference 2004, San Francisco, April 2004 Page 2 Outline Yabulu Refinery Overview Business Systems Architecture Yabulu Refinery Performance Measures Other Business Benefits Questions

3. OSI PI Users Conference 2004, San Francisco, April 2004 Page 3 Overview P H I L I P P I N E S I N D O N E S I A A U S T R A L I A N E W C A L E D O N I A Hinatuan Gee Gebe Yabulu Greenvale Brisbane Karembe Teoudie Baie Ugue Kouaoua Boakaine Nakety Noumea Rio Tuba Taganito BHPBilliton’s nickel business Operations in Australia and Colombia World’s 5th largest nickel and cobalt producer 3.5 M tpa of imported ore produces 32 000T Ni and 2000T Co Employs 700 people Yabulu Ore Sources

4. OSI PI Users Conference 2004, San Francisco, April 2004 Page 4 Yabulu Refinery Overview Water recycling facility 3TP Nickel Compacts

5. OSI PI Users Conference 2004, San Francisco, April 2004 Page 5 Yabulu Refinery Overview cont... 6 Control Rooms Mixture of Different Control Systems PI installed November 2000 Administered by IT Department Champions in each Business Unit Refinery BSC Reporting Implemented FY03

6. OSI PI Users Conference 2004, San Francisco, April 2004 Page 6 Business Systems Functional Hierarchy PIMS Incident Mgt First Priority LMS Traccess Sales & Marketing MSAP Accounting, Maintenance, HR, Supply QSAP Ore Ship & Train Scheduling G2 DCS System6 & PLC’s Expert System Connoisseur Expert System Connoisseur Data Historian (OSI PI) LIMS CCLAS Reconciliation  fine Risk Mgt RMS2000 Asset Mgt Activa Plant Mass Balancing Metsim KPI & Advanced Calcs PI-ACE KPI & Advanced Calcs PI-ACE Forecasting MS Excel Alarms PI-SQC Alarms PI-SQC Production MS-SQL MSDS’s ChemAlert

7. OSI PI Users Conference 2004, San Francisco, April 2004 Page 7 Automatic PIMS Interfaces PIMS SAP R/Link-PM  Excel  Excel PI-SDK MSDS’s HTTP   Weather Station PI-RDBMS LIMS PI-RDBMS Σ Statistica PI-ODBC Intranet PI-ODBC Crystal Reports Crystal Reports PI-ODBC

8. OSI PI Users Conference 2004, San Francisco, April 2004 Page 8 Yabulu Balanced Scorecard

9. OSI PI Users Conference 2004, San Francisco, April 2004 Page 9 Example Business Unit Scorecard

10. OSI PI Users Conference 2004, San Francisco, April 2004 Page 10 Production & Efficiency - Nickel Plant Critical calciner KPI’s monitored in real-time

11. OSI PI Users Conference 2004, San Francisco, April 2004 Page 11 Production & Efficiency - Roasters

12. OSI PI Users Conference 2004, San Francisco, April 2004 Page 12 Production & Efficiency - Roasters % of time temperature was within ±10°C of SP during the last 6 hours

13. OSI PI Users Conference 2004, San Francisco, April 2004 Page 13 Production & Efficiency - Grinding Compare KPI’s between Shifts Peak power is purchased at higher rate than off-peak

14. OSI PI Users Conference 2004, San Francisco, April 2004 Page 14 Production & Efficiency - Dryers Operator log for entering reasons for downtime events Uses PI Alarm tags as triggers, and events saved in SQL table /SQL="select COUNT(*),0 from dtmPrimary where Equipment1 = '320' AND StartTime > ?;" P1='PE.680.TS.Today'/VL

15. OSI PI Users Conference 2004, San Francisco, April 2004 Page 15 Production & Efficiency - Dryers Downtime summary report, using Crystal Reports Adhoc reports executed from Excel / MS Query for maintenance reporting Downtime summary report, using Crystal Reports Adhoc reports executed from Excel / MS Query for maintenance reporting

16. OSI PI Users Conference 2004, San Francisco, April 2004 Page 16 Production & Efficiency - Dryers Equipment tree and reason sets stored in PI-MDB

17. OSI PI Users Conference 2004, San Francisco, April 2004 Page 17 Production & Efficiency - Dryers Downtime Service RTDB -Trigger Tags MDB -Equipment Tree -Reason Sets -DB Connections SQL DB Configuration Tool (OCX Control) Downtime Client (OCX control) Developer’s PC SQL Server PI Server Downtime monitor data flows

18. OSI PI Users Conference 2004, San Francisco, April 2004 Page 18 Production & Efficiency - Metallurgical Accounting Sigmafine used to perform monthly reconciliations for nickel and cobalt Allows flowsheet mass balance to identify unmeasured losses Input data can be read from PI tags or csv file Has allowed monthly Metallurgical Accounting reports to be completed in 1 working day Report on intrinsic data quality i.e. meter & weigher accuracy

19. OSI PI Users Conference 2004, San Francisco, April 2004 Page 19 Production & Efficiency - Metallurgical Accounting Flowsheet in Sigmafine used for monthly nickel and cobalt reconciliations

20. OSI PI Users Conference 2004, San Francisco, April 2004 Page 20 Production & Efficiency - Metallurgical Accounting Report on measured and reconciled mass through each meter Report on data quality and quality of mass balance

21. OSI PI Users Conference 2004, San Francisco, April 2004 Page 21 Profitability & Growth - Project ROI Calculate payback from improvement projects by writing current nickel & cobalt prices to PI tags, and using in Data Sets

22. OSI PI Users Conference 2004, San Francisco, April 2004 Page 22 Environment & Community - Stack Discharges Using SQC Chart Histogram for MTD KPI’s Double clicking chart title bar display statistics

23. OSI PI Users Conference 2004, San Francisco, April 2004 Page 23 Health & Safety - CRO Logs Operator names recorded in PI string tags Safety & training stats and text saved in SQL Server PI Trend showing tank levels for duration of shift

24. OSI PI Users Conference 2004, San Francisco, April 2004 Page 24 PI-ACE used to write monthly measures to BSC database BSC database connection string stored as property in MDB BSC Measure tags saved as aliases in MDB MeasureID stored in “UserInt1” tag attribute Other Business Benefits - Updating BSC Using PI-ACE

25. OSI PI Users Conference 2004, San Francisco, April 2004 Page 25 Other Business Benefits - Updating BSC Using PI-ACE

26. OSI PI Users Conference 2004, San Francisco, April 2004 Page 26 Other Business Benefits - Process Capability for ISO9001 For a process that is normally distributed it is known that 99.73% of all values are within the ± 3 sd around the mean Review data which falls outside this range to determine the cause. Exclude this data if the process was unstable Calculate process capability based on a 95% confidence level around the process mean This is what we know the process is currently capable of achieving. Configure PI-RTSQC Alarms for when process goes outside these control limits, and raise incident in FirstPriority

27. OSI PI Users Conference 2004, San Francisco, April 2004 Page 27 QNI PIMS Scorecard How up to date is the production information published on our intranet ?    At what level of detail do we compare performance ? What interval is performance data tracked ? Who has access to this data ? How do we collect downtime ?

28. OSI PI Users Conference 2004, San Francisco, April 2004 Page 28 Questions ?