rodrigo andai – enterprise software - abb
TRANSCRIPT
IT/OT Convergence in MiningRodrigo Andai – Enterprise Software
ABB Mining Vision
To drive fundamental change in the way a Mining Enterprise works, creating dramatic increases in
Health and Safety
Productivity
Predictability
Asset Availability
Energy Efficiency
Quality
What is IndustrialIT?
In simple terms Industrial IT is ABB's commitment to real time integration of automation and information systems across the business enterprise.
IndustrialIT
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VP Health, Safety & Compliance|
VP OPS
CFOCIO
VPProcurement
KW-hours/ton
Delay penalties per month
Equipment-incidents /
month
Ship over-under load/month
Drill-blast cost/ton
Reagents/ton
Fuel/ton
Dig rate by shovel
DilutionAvailability
Throughput
Shipping queue length
IndustrialIT – Mining
IT and OT Convergence – IndustrialIT
Infrastructure Control Devices Communications Control Software Industry Apps Work & Assets Supply Chain Admin
• Mining• Power• Retail• Port• Automation
• RTU• Intelligent devices
• High-speedcommunication infrastructure
• Automation and control
• Distributionmgmt system
• Plant operations
• Security
• Mining execution (planning, sales and logistics, labmgmt, production accounting)
• Energy outage mgmt
• Energy portfolio mgmt
• Work mgmt• Asset mgmt• Equipment reliability
• Mobile Work
• Materials mgmt
• Procurement• Inventoryoptimization
• Finance• Human resources
Industrial Enterprise Lifecycle
Breadth spanning the entire asset intensive lifecycle
IT/OT Convergence Transforms Real-time Data into Actionable Insights That Drive Operational Excellence
Information Technology Synthesizes big data into critical insights and automated actions
Insights drive just-in-time work to optimize enterprise
Large volumes of data for visibility
into condition and status
Operational TechnologyMonitors and controls critical assets
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Benefits of the IT/OT Converged Enterprise
Respond fasterto real time conditions
Gain insight for business process improvement
Prioritize work to reduce the risk of outages
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Production Control and Optimization
Plant Feed Monitor Scope
Mining Activities
Processing
Transportation
Top Soil Drilling Overburden Waste Dump Parting Removal Loading Hauling Reject Disposal Rehabilitation
ROM StockpilesHauling Processing Plant Product Stockpiles Load Products
Transporting Train Loading Ship LoadingPort StockpilesTrain UnloadingRail HeadStockpiles
The real environment…
Business Case: Plant/Mill optimization
Better ore grinding due to integration of automation layersTechnologies: Inventory Management and Model Predictive Control
Problem
Ore variability (mineralogy, hardness, composition) is the largest source of disturbance for process stability and performance in ore processing plants, grinding and flotation
If ore properties we known ahead the processing plant can be prepared ahead and minimize the effect on production and quality
Solution
as pile is built, use inventory management solution MineMarket to store ore properties in 3D stockpiles models
Retrieve the ore property information in real time to be used by model predictive controller implemented in 800xA
Business case
Customer: higher performance and process stability
Customer data shows that improvements worth tens of millions of dollars are achievable
The inability to manage the quality of material coming into the plant results in the following challenges:
Poor plant efficiency e.g. inability to tune plant operating parameters to specific feed properties such as hardness, liberation size, floatability, etc.
Additional maintenance e.g. blindness of feed properties allows equipment to potentially be used beyond operating specifications
Higher energy consumption e.g. grinding is the most energy-intensive part of a mining operation
Less-than-optimal productivitye.g. hardness drives throughput in hard rock comminution
ABB Plant Feed Monitor – Business Challenges
Leverage interface of Information technology (IT) and operational technology (OT)
Feed information from existing IT infrastructure (e.g. ore movements and properties) forward into the process control environment to ‘tune’ plant to ore characteristics
MineMarket manages material logistics and tracks ore properties from face through value chain
ABB Advanced Process Control module used model predictive control to manage and stabilize plant environment
Solution = ABB ES MineMarket + ABB Advanced Process Control
ABB Plant Feed Monitor - Solution
Inventory management and MPC for optimal ore grinding
Architecture
©2009 Mincom Confidential | 15
800xA
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3
5A
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8 Legend:
1: Yard machinery status data 2: Online analyzer quality data3: Flow rate, position, direction (very minute)4: Quality data (every minute)5A: Aggregated (stack/reclaim transactions (*)5B: Aggregated quality data (*)6: Stockpile breakdown query 7: Stockpile breakdown response8: Control signals (reclaiming)9: Feed characteristics (moisture, hardness etc.)10: Visualisation (Smart Client)11. Advanced Process Control
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5B
XML
Fe, Si, Moist, Hardness
Standard 800xA Plug-in
SensoryData
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Use Case APC in Grinding : Stockyard
APC in Grinding : MineMarket
Use Case APC in Grinding : Controller
Inventory management and MPC for optimal ore grinding
Mill controller on the right learns about the pile change and its ore properties. The left one does not. Controller able to react before process disturbance is seen in the signals.
Benefits
Higher production
Less energy consumption per ton
Use Case: APC in Grinding
Mill controller learns early about the pile change and its ore properties. It can adjust feed rate faster according to conditions,
Benefits
Higher production
Less energy consumption per ton
Mill/Concentrator operations leveraging IT/OT convergence
The old way:
Production, equipment and other control systems not integratedNo information on relative product pricingNo information on feed materialPlant set points static
Value Proposition
Increase plant recovery and optimize energy consumption of ore feed properties through integration of processes and business systems
Advanced process control (APC)
manages grinding and flotation in real-
time (OT)
Models and real-time material tracking
provides short term feed characteristic
schedule to APC(IT)
On stream analyzers in plant reconcile actual feed with
geological model to further improve
predictability and optimization
(OT)
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APC refines control set points to
optimize energy consumption and
recovery (IT)
Optimization and logistics models
provide update on short term feeds
(IT)
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Asset Optimization
More control in the AlarmsWork Orders created real timeOption to do SchedulingCosts included in the Work Order
Automatic Alarm Work Order Creation:
The Control System shows an Alarm and the operator open an Ellipse Template with all the basic information:
• Equipment• Alarm Description• Work Order Type – Option to modify•Maintenance Type – Option to modify
Additional information can be included if need itSelect option on Work Order creation and Ellipse send the Work Order number back to template (800xA).
Benefits:Possibility to include Calculated Resources (People, Materials and EquipmentKeep History of all the AlarmsWork Order analysis
Operation Statistics Data:
The information Management (Historian) send the Data information to the Operation Statistics file, Statistics like:
• Operation Hours• Tonnage• Water and Mineral Ratio• Density
In combination with the Maintenance Schedule Tasks and the Batch Process, Ellipse creates the Schedule Jobs for the future
Benefits:Maintenance Annual PlanMaintenance PlanningProjection of resources need it in the future (People, Materials, Equipment)Reduction on Inventory and Costs
Possibility to do Schedule jobsPossibility to include jobs in the shutdowns - outagesHistory of all the work ordersPossibility to see costs by statistics types
Equipment
FinancialTrans-actions
Budget / ActualBudget / Actual
$ / Statistics
Account
Budget / ActualBudget / Actual
ProjectOperating Statistics
Maintenance Schedules
Condition Monitoring
Inspections& Defects
DCS(800xA)
StandardJobs
Roster T&A Leave Training
Work Group
Parts, People & Equipment
Goods Issue from
Warehouse
Replenish-ment
Purchase Order
Receive Goods and
Services
EnterTime Payroll
Labor Costing
Invoice
Project
Work Order
Account
Plan/ActualProduction
Statistics
RequisitionsReactive
Work
Bulk Commodities
AP Pending
ApprovedInvoice
3-way match
PlanWork
AssignWork
DoWork
Person
Goods
Goods & Services
Accrue commitment
s
Expense & release
commitment
Payment
Expense
Reconcile Labor Rates
Budget / ActualBudget / Actual
Work Order
$ / Statistics
ActualActual
Equipment
Performance Reporting
(KPIs)
Expense
Expense
DepreciationFixed Assets
InvoiceAR
Revenue
Automatic Alarm Work Order / OperationsStatistics
Transform real-time and historical asset data into strategic insights on the health of your mission critical assets.
Key Benefits
Asset Condition Data Availability
Consolidate data on asset and their condition and make available to key stakeholders in timely manner
Optimize use of Local Knowledge Deployment of advanced decision support tools
Early warnings on failureProvide visibility and increase awareness of potential failures to support operational decision making
Improve Asset Utilization Information availability enables maintenance to be delayed on healthy assets
Condition-based maintenance Provide a path and strategy to applying condition-based maintenance strategy to asset portfolio
Improve workforce productivity and governance
By enabling field workforce to with mobile asset management
Top benefits How we can help
Built for asset intensive industries, ABB has the leading EAM solution with OT / IT convergence.
Key Benefits
Asset Condition Data Availability
Optimize use of Local Knowledge
Early warnings on failure Improve Asset Utilization
Example Business Outcomes
10%
7%Condition-based maintenance
Improve workforce productivity and governance12% 9%
800xA
MIN
ING
The future of Mining… IndustrialIT
Questions?
