· About Hindustan Zinc Limited
Hindustan Zinc Limited [HZL] is a leading Indian integrated mining and resources producer of zinc, lead, and silver. It is a subsidiary of Vedanta Limited and operates the world's second-largest zinc mine, with a focus on sustainable mining practices and technological innovation. HZL's operations span multiple mines and smelting facilities, contributing significantly to India's metal industry while prioritizing environmental stewardship and community development.
· Abstract:
Vedanta Hindustan Zinc Limited, spearheaded the integration of the Aveva PI system with a diverse array of data sources, including ABB, Epiroc, Cisco, Rockwell, Yokogawa, Honeywell, Etc. This intricate project required expertise in handling various data communication protocols: OPC DA/UA for DCS/PLC, Modbus for SCADA, APIs for cloud-based databases and IoT gateways, SQL databases for LIMS and telemetry data, and manual data entry via data loggers.
Via this solution we improved the reliability Health index and performance monitoring of critical assets, OEE, Material dispatch planning, mobile equipment OEE, Particle size prediction in mills. These use cases have helped us improve the operational efficiency of the plant and generating enormous amount of tangible and Intangible ROI.
· Problem Statement:
At Hindustan Zinc Limited faced we faced operational challenges, such the lack of real-time reliability data for assets and unknown operational efficiency metrics. The operating point of GRO was also unclear, and process capability and score analyses were conducted offline. The marketing team relied on email and phone conversations to determine actual stock availability, leading to inefficient loading and dispatch planning. Excessive idling of trucks in the mines and inconsistencies in the changeover of standby pumps resulted in availability losses due to inadequate preventive maintenance and extended non-operational periods. Additionally, the key operational parameter of particle size [P80] was not consistently monitored in real time, further complicating process optimization efforts.
· Approach:
Hindustan Zinc Limited addressed its operational challenges by integrating local PLC systems with OSI-PI and identifying key parameters and their design limits. They developed real-time reliability health index monitoring templates using PI-AF, enabling automated alerts and condition-based notifications to SAP. Efficiency was monitored in real-time based on OEM performance curves, and ideal versus actual power consumption was analyzed. Recovery analysis and grade versus recovery dashboards were created in PI-AF, along with CpK and scorecard analyses. Real-time dashboards with SPC charts and notification alerts were developed. Stock levels were monitored and alerts were sent to relevant personnel. Idle time analysis and dashboards were developed, and asset-specific displays were provided on vehicle tablets. SAP-PM notifications and standby changeover alerts were triggered based on running hours. The real-time status of all assets was tracked, and energy monitoring devices were integrated with PI across HZL. Real-time dashboards of actual power consumption and auto alerts for 15-minute block schedule deviations were also implemented. Through these measures, HZL successfully utilized the AVEVA PI system to enhance operational efficiency and asset performance.
· Benefits:
The project provided Hindustan Zinc Limited with several significant benefits, including:
1. Enhanced Asset Reliability: Real-time monitoring and health index tracking improved the reliability and maintenance of assets, reducing downtime.
2. Improved Operational Efficiency: Real-time efficiency monitoring and performance analysis enabled optimization of operational processes.
3. Optimized Resource Utilization: Ideal vs actual power consumption analysis helped in reducing energy waste and optimizing power usage.
4. Increased Recovery and Grade Performance: Continuous monitoring and analysis of recovery and grade parameters improved overall production performance.
5. Streamlined Stock Management: Real-time stock analysis and automated alerts ensured better inventory management and reduced inefficiencies in loading and dispatch planning.
6. Reduced Idle Time: Idle time analysis and dashboards enabled better utilization of trucks and other equipment in the mines.
7. Proactive Maintenance: Automated alerts and condition-based notifications led to more effective preventive maintenance, reducing unplanned downtime.
8. Improved Decision Making: Real-time dashboards and SPC charts provided valuable insights, facilitating data-driven decision-making.
9. Effective Communication: Automated notifications and alerts improved communication and coordination among different teams.
10. Reduced Carbon Footprint via Energy Efficiency: Integration of energy monitoring devices and real-time power consumption dashboards led to better energy management and cost savings.
Compliance and Standards: CpK and scorecard analysis ensured adherence to quality and performance standards.