maximising control, visualisation and information at the mix plant at lonmin
TRANSCRIPT
Maximising control, visualisation and information at the Mix plant at Lonmin
Brian Davies Senior Technician
Roelf BoshoffSI Engineer
Agenda
IntroductionIntroductionIntroductionIntroduction
The ProjectThe Project
Benefits of version 3 graphicsBenefits of version 3 graphics
ConsiderationsConsiderations
Technical ChallengesTechnical Challenges
Introduction to Lonmin
► World’s third largest Platinum producer
► Operations based in South Africa▪ North West▪ Limpopo
Introduction to Mix Concentrator
Mix Concentrator processes► Stock pile and raw ore conveyor system
▪ Raw ore stockpiles▪ Conveyed to 40 m silos▪ 4 to 5 grams of PGM's per ton
Introduction to Mix Concentrator
Mix Concentrator processes► Milling
▪ Raw ore fed into ball mill▪ Diluted with water - Slurry▪ Cyclones separate fine from coarse▪ Coarse returned to mill
Introduction to Mix Concentrator
Mix Concentrator processes► Floatation
▪ Chemicals used to attract PGM’s to bubbles ▪ Primary roughers extract 80-90%▪ Secondary roughers collect rest▪ Contaminants removed in cleaning section
Introduction to Mix Concentrator
Mix Concentrator processes► Thickener – cone shaped
▪ Feed into centre of cone – 90% of solids▪ Solids settle to bottom - flocculants▪ Lighter particles settle on outside – less turbulent▪ Rake particles to centre at 0.12 RPM▪ Pumped from centre
Mix Plant Network Topology
Allen-Bradley Workstation
ArchestrA IDEWorkstation
ControlSwitch
ProductionSwitch
AOS 1
AOS 2
INSQL
GalaxyRepository
MIX PLC 1 MIX PLC 2 MIX PLC 3 MIX PLC 4 MIX PLC 5
IntroductionIntroduction
Agenda
The projectThe projectThe projectThe project
Benefits of version 3 graphicsBenefits of version 3 graphics
ConsiderationsConsiderations
Technical ChallengesTechnical Challenges
The Project
► Replace TI PLCs with Allen-Bradley PLCs
► Reprogram PLC code using standard routines made possible by using an Allen-Bradley PLC
► Rebuild SCADA using ArchestrA and version 3 graphics▪ Build a modern looking SCADA ▪ Create a standard graphic library for Mix Concentrator▪ Establish a system which is easy to expand and
change using the ArchestrA architecture
The projectThe project
IntroductionIntroduction
Agenda
Benefits of version 3 graphicsBenefits of version 3 graphicsBenefits of version 3 graphicsBenefits of version 3 graphics
ConsiderationsConsiderations
Technical ChallengesTechnical Challenges
Benefits of version 3 Graphics
Why version 3 graphics?
► The superior graphics (Pretty pictures)► Have all the graphics in one place► Inserting graphics into SCADA is easy ► Graphics can be reused► Added benefit of connection status indication
Benefits of version 3 Graphics
Superior Graphics
► Enhanced Graphics► Esthetically Pleasing► Realistic Graphics► Air of Professiolism
Benefits of version 3 Graphics
► Enhanced Graphics
Transparency
Embossed Symbols
Patterns
Benefits of version 3 Graphics
► Esthetically Pleasing
Lighting Effects
Shaded Tanks
3D Symbols
Benefits of version 3 Graphics
► Realistic Graphics
Oil Filter
Solenoid Valve
Mill displaying gears
Animated Fan
Benefits of version 3 Graphics
► Air of Professiolism
HMI Time
PLC Time
Control Logix PLC
Allen Bradley DeviceNet
Benefits of version 3 Graphics
Have all the graphics in one place(Forcing Standards)
► Add symbols to template
► Link popups to icons
► Populate graphics with attributes
ArchestrA supplied the means to create Standard Templates
With version 3 graphics:
Benefits of version 3 Graphics
► Add symbols to template
Popup Graphics
Icon GraphicsGraphic
DescriptionInherited from Master template
Referenced as me.PopUp
Benefits of version 3 Graphics
► Populate graphics with attributes
Template Attributes
Icon Graphic
Benefits of version 3 Graphics
► Link popups to icons
Reference Popup Graphic
Icon graphic
Activate as Icon
Show popup on click
Example Popup
Benefits of version 3 Graphics
Inserting graphics into SCADA is easy
ArchestrA instance
Symbols embedded in instance
Embed ArchestrA Graphic
Benefits of version 3 Graphics
Inserting graphics into SCADA is easy
Symbol embedded in SCADA
Benefits of version 3 Graphics
Graphics can be reused
► Another Graphic► The SCADA► Template as embedded graphic
After graphic is created in graphic toolbox it can be reused in:
Benefits of version 3 Graphics
► Graphic used in another Graphic
Another GraphicAnother Graphic
Graphic from graphic toolbox
Original graphic
Embedded graphic
Benefits of version 3 Graphics
► Graphic used in the SCADA(Where graphic is not an icon)
Tag entered in Scada
Graphic from graphic toolbox
Benefits of version 3 Graphics
► Graphic used in a template(Graphic becomes an icon)
Graphic from graphic toolbox
ArchestrA template
Symbol nameIcon used in
SCADA
Tag already assigned
Benefits of version 3 Graphics
Added benefit of connection status indication
* Status icon indicates status of the connection to the IO server
Add status Indication
Status indication definitions
Status added to Icon
Benefits of version 3 Graphics
How did version 3 graphics benefit me?
► Reduced number of windows to maintain► Reduced development time – More time to
focus on optimizing plant► Simplified the development – Any
technician can do development► Graphics self-explanatory – Less time
needed to train operators
Benefits of version 3 graphicsBenefits of version 3 graphics
The projectThe project
IntroductionIntroduction
Agenda
ConsiderationsConsiderationsConsiderationsConsiderations
Technical ChallengesTechnical Challenges
Consideration
► Do not use minimum hardware specifications for GR▪ Might cause instability,▪ Performance issues,
► Network stability▪ Communication failure
ConsiderationsConsiderations
BenefitsBenefits
ObjectiveObjective
IntroductionIntroduction
Agenda
Technical ChallengesTechnical ChallengesTechnical ChallengesTechnical Challenges
Technical Challenges
Flushing Sequence Popup
► To clean a pump that carries slurry before stopping and starting
► Typical arrangement:
Flush Valve
Delivery ValveSuction Valve
Slurry Pump
Drain Valve
GSW Analog
GSW Valve
* Many different configurations exist
Technical Challenges
Flushing Sequence Popup
All the slurry pumps need flushing valves
Not Enough space to display flush valves – Need a popup
Technical Challenges
Flushing Sequence Popup
Flush Button Opens
Flush Button Indicating problem in flush sequence
7 valve positions 3 types of pumps Analog only constant 15120 possible
configurations
Flush popup template graphic
Technical Challenge
► HOW was it done?▪ Created a flush template▪ Popup graphic embedded in template▪ Populate popup graphic with dummy icons▪ Define equipment in instance of object▪ Use OwningObject scripts to assign equipment
Flushing Sequence Popup
Technical Challenge
► End result
Flushing Sequence Popup
Completely dynamic popup
Technical Challenges
PLC LayoutWHY?
Indicate module status
Show Inter-PLC communication
Fault Finding
Grapical devicenet represenation
Technical Challenge
► A standard naming convention makes Archestra templates possible
► Naming convention example:▪ Rack R01▪ Slot S04▪ Slot in a rack: R01S04
► Templates created to assign the IO automatically using the naming convention and containment
PLC Layout
Technical Challenge
► Templates created and their containmentPLC template – assign PLC path
Rack Template – module status indication
Devicenet template – DNB module
CN2DN templateDevicenet template – CN2DN module
Rack Template
► Example Layout of containment:
PLC Layout
* Contained name very important* PLC path propagated to assign IO
Technical Challenge
PLC Layout
► The OLD methodTags Needed for a single Devicenet Scanner
Tags Needed for Slot Status of a single Rack
Tags Needed for:
• One PLC
• Six Racks
• Two Devicenet Scanners
► The NEW method
Technical Challenges
Effective alarm annunciation and navigation
► Old methods used▪ Button to open a single alarm list▪ Indicate last four alams on top menu
► 1st stage of new method▪ Divide alarms into four groups ▪ Add animation to indicate alarms▪ Navigate to alarm list
► 2nd stage of new method▪ Display critical alarms on top menu▪ Display mouse-over descriptons▪ Shown critical alarm count▪ Add action to navigate to window and popup
Technical Challenges
Effective alarm annunciation and navigation
BUTWith the new and improved system▪ Alarms can be acknowledged from the popup▪ Type of alarm and priority also indicated
Icon indicating alarm (Red)
Alarm acknowledgement button
Alarm latch in PLC indication
Separate button for reset and
acknowledgement
Alarm Priority
Technical Challenge
► HOW was it done?▪ Create Alarming template▪ Add attributes to all templates which can alarm
• WindowName
• AlarmingEnabled
• AlarmType
▪ Use Intouch alarm viewer controls to capture alarms▪ Use owning object scripts to populate graphics▪ Link windows to alarms
Effective alarm annunciation and navigation
Thank you for attendingWonderware User group
Conference 2009
Any Questions?