ABB Future of mining; automating mining processes by Llewellyn Best
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The document discusses the future of automation in the mining industry. It outlines trends toward increased automation and unmanned operations to improve safety and productivity. Specific areas discussed include automated material handling using conveyors, machine control for yard operations, integrated material tracking systems, and centralized intelligent operations. The presentation also describes ABB's solutions for automated mining processes including conveyor control programs, machine automation, and a collaboration model to integrate people and systems.
ABB Future of mining; automating mining processes by Llewellyn Best
- 1. Llewellyn Best, PAIS, ABB Australia Future of Mining Automating Mining Processes © ABB Group November 4, 2013 | Slide 1
- 2. Future of mining Industry Trends Increasing focus on automation and autonomy Increasing focus on leveraging skills through technology Unmanned mine operations for safety and improved productivity Demand for integrated view of operations I.e. Remote operations Standardisation of system for reuse on sites across the Enterprise Improved collaboration © ABB Group November 4, 2013 | Slide 2
- 3. Future of mining Topical Areas © ABB Group November 4, 2013 | Slide 3
- 4. Future of mining Challenges ? Ore Extraction ? Deeper, Steeper, Smarter, Cheaper ? Material Tracking Systems ? Automating Yard-Machine Operation ? Intelligent Tracking and Decision making ? Stockpile Modeling ? Simplifying the maintenance tasks ? Safer, Easier, Faster ? Remote Control with Intelligent Decisions ? Remote Control ? Remote Maintenance ? Remote Integration © ABB Group November 4, 2013 | Slide 4
- 5. Future of mining Agenda Material Handling Mining Conveyor Control Program Machine Automation, Material Tracking and Stockyard Management Remote Access for Maintenance and Diagnostics Maintenance Automation Centralised Intelligent Operations © ABB Group November 4, 2013 | Slide 5 Multisystem Interconnect
- 6. Material Handling Mining Conveyor Control Program © ABB Group November 4, 2013 | Slide 6
- 7. Conveyor Solutions Traditional Approach November 4, 2013 | Slide 7 Master drive speed controlled © ABB Group Master / Follower Follower drive(s) torque controlled
- 8. Conveyor Solutions MCCP Approach Torque Ref Drive 1 Speed_Set_Value RAMP f(x) Ramped_Set_Value Speed Set Value 0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 % Speed Drive 1 Speed Dependant Tq Torque 0% y1 % y2 % y3 % y4 % y5 % y6 % y7 % y8 % y9 % y10 % Drive 1 Torque Ref Drive 2 Speed Drive 2 Derivative Torque Torque Reference Drive 2 Speed Deviation PI Control Torque - Torque Ref Drive 3 Start-up and Stop control Speed Drive 3 Drive 3 E1 Start/Stop Speed_Average E2 k k=4 Average value of measured speeds from all drives is measured Overriding speed control © ABB Group November 4, 2013 | Slide 8 Torque Ref Drive 4 Speed Drive 4 Drive 4
- 9. Conveyor Solutions MCCP Control Software package for ACS800 Single Drive or Multi Drive Running on Drive Control Unit (RDCU) DDCS Drive Enable Start/ Stop Complete Control Speed Ref RDCU © ABB Group November 4, 2013 | Slide 9
- 10. Conveyor Solutions MCCP Features – Start / Stop Sequence © ABB Group November 4, 2013 | Slide 10 Safe Stop and Start Sequences Safe and Reliable Integrated Brake Control Safety First!
- 11. Conveyor Solutions MCCP Features – Emergency Operation Mode User friendly Emergency operation mode M 3 © ABB Group November 4, 2013 | Slide 11 M 3 M 3
- 12. Conveyor Solutions MCCP Features – Hi-Speed Communication High speed bi-directional Communication Accurate load sharing Feedback of drives used (status, actual speed, torque) Cycle time <5ms Fast control loop for high dynamics and accuracy DDCS CH2 High speed communication to supervisory system not required Minimised motion control logic in supervisory controller Less controller performance needed Fault and Alarm processing © ABB Group November 4, 2013 | Slide 12 Shows only required Faults and alarms DDCS RDCU
- 13. Conveyor Solutions MCCP Benefits Less supervisory controller capacity needed November 4, 2013 | Slide 13 Increased Reliability / Decreased Downtime Reduced Commissioning Time $$$ Safe and consistent software © ABB Group $$$ Easy Conveyor tuning by DriveWindows Reduced Lead Time and lower cost Motion monitoring and protection Maintain existing Site Standards Lower engineering hours and effort $$$ Open to every control system Lower Cost, reduced Complexity Reduced Training Costs $$$
- 14. Material Handling Yard Machines, Material Tracking & Stockyard Management © ABB Group November 4, 2013 | Slide 14
- 15. Material Handling The Aim of Stockyards Stockyards connecting consecutive steps in materials transportation chains with different time frames Mixing and blending different charges to achieve a certain quality of the outgoing material Providing a buffer for material reserve to next continuously operating processing steps in the chain. © ABB Group November 4, 2013 | Slide 15 One or multiple inputs, different qualities One or multiple outputs, single or different qualities
- 16. Material Handling Machine Automation Advanced automation / unmanned operation Area level Electrification, instrumentation & automation packages Train loading & unloading © ABB Group November 4, 2013 | Slide 16 Belt conveyor system Stacker/ reclaimer Ship loader/ ship unloader Scanning/ GPS/analyzer
- 17. Material Handling Fully Automated Stacking November 4, 2013 | Slide 17 Stacking exact into the specified stockpile profile © ABB Group Fully automated stacking assures the execution of appropriate stacking method (Coneshell, Windrow, ..) Reduced dust by adjustment of the boom close to the top of the pile
- 18. Conveyor Solutions Fully Automated Reclaiming Reclaiming also in poor environmental conditions due to continuously updated stockpile shape model Smooth continuous operation reduces wear and tear November 4, 2013 | Slide 18 Operation supported by 3D laser scanner for shape detection and RTKGPS receivers for exact positioning © ABB Group Fully automated reclaiming based on stockpile shape and volume model Reduction of air digging
- 19. Material Handling Machine Tracking and Monitoring / Anti-Collision GPS / Laser positioning Calculating and movement measurement and prediction Touch probes © ABB Group November 4, 2013 | Slide 19
- 20. Material Handling Measurement Integration Monitors the material flow of bulk material and supplies real time stockpile tracking by tonnage and grade. November 4, 2013 | Slide 20 Tracking of materials to the discharge point © ABB Group Monitoring of masses/volumes on belt conveyors Dynamic display of belt load with color differentiation according material type
- 21. Material Handling Automated Routing and Re-Routing © ABB Group November 4, 2013 | Slide 21
- 22. Material Handling Quality Control Shows material origin and material owner Qualities will be tracked, starting at the receiving chute of a belt conveyor, along the belt conveyor until it was spread onto the pile or loaded on a train/ship November 4, 2013 | Slide 22 Laboratory system integration for automated data collection. © ABB Group Tracks actual and forecast (planned) material movements coordinates blending and mixing
- 23. Material Handling Visualisation Virtual stockpiles November 4, 2013 | Slide 23 Presentation of stored material at its place © ABB Group Presentation of all fix assets (belt conveyors distribution towers) and mobile machines (stacker, reclaimer, ship loader/unloader) Block / allocate areas
- 24. Material Handling Stockyard Technology Integration Advanced control Operating & dispatching level Area level Overall plant monitoring Control of conveyor drive and shifting heads Calculation of a real time 3D terrain model Fully automated stacking and reclaiming Collision avoidance of yard machines between Material manager themselves Collision avoidance of yard machines with piles and Stockyard management Stacking/ fixed obstacles Pile monitoring Quality Material Stacking / Anti reclaiming & visualization management tracking reclaiming collision technology & visualization technology cystem Data exchange Electrification, instrumentation and automation Basic control Train loading and Machine control and automation loader/ Belt Stacker/ Ship Scanning/ local conveyors Stacker/ ship unloader GPS/analyzer unloading PLC and with operator on the machine reclaimer all interlockings and safety features active reclaimer © ABB Group November 4, 2013 | Slide 24
- 25. Centralised Intelligent Operations Collaboration Model © ABB Group November 4, 2013 | Slide 25
- 26. Centralised Intelligent Operations Collaboration Model Asset Management, Financial Management, HR, ERP Functionality Mass balancing and production accounting Material logistics and billing Data integration, devi Mine Planning ce integration, mai Predictability, optimization, scheduling Assay Management ntenance Quality Management Planning and Scheduling Open, integration of people Extended Process Control and systemsPCS Human Resources Geological Exploration & Evaluation © ABB Group November 4, 2013 | Slide 26 Mine Plan Mine Operation Energy Resources ROM Process Plant Product Stockpiling Water Resources Product Transport Reclaiming and Loading Shipping Sales
- 27. Centralised Intelligent Operations People, Systems and Equipment Collaboration © ABB Group November 4, 2013 | Slide 27
- 28. Centralised Intelligent Operations Changing the Way We Operate One common way to handle all functions One common user language One way of working November 4, 2013 | Slide 28 A plant centric view of all information independent of system © ABB Group Everyone gets the same view of plant activities Information sharing without barriers
- 29. Centralised Intelligent Operations Mining Operational model supported by ISA-S95 Collaborate OIC ROC CCR Monitor & © ABB Group November 4, 2013 | Slide 29 Control
- 30. Integration Platform – System 800xA Improving Operator Effectiveness… Documentation Field Device and Asset Optimization History / Reports Information Integration • Predefined process objects Trends • Information availability • Standardized look and feel • ACL controlled visibility • Faceplates, Graphic Symbols • Alarm management • Trend, History • Documentation Model Object Faceplate, Alarms Graphic & Video • Device Management • Asset Monitor, MMS • Etc…. • Library types • One change automatically affects all instances… ENTERPRISE WIDE! LICA 101 Control Function Real Object © ABB Group November 4, 2013 | Slide 30
- 31. Integration Platform – System 800xA The Power of Integration Substation Automation IEC 61850 © ABB Group November 4, 2013 | Slide 31
- 32. Integration Platform – System 800xA The Power of Integration Process Electrification Modulebus PROFIBUS DP © ABB Group November 4, 2013 | Slide 32
- 33. Integration Platform – System 800xA The Power of Integration Process Instrumentation Modulebus HART PROFIBUS DP/PA FOUNDATION Fieldbus H1/HSE © ABB Group November 4, 2013 | Slide 33
- 34. Integration Platform – System 800xA The Power of Integration Safety applications Modulebus for S800 HI I/O All other communication for non-SIL applications © ABB Group November 4, 2013 | Slide 34
- 35. Integration Platform – System 800xA The Power of Integration PLC connectivity PLC Connect OPC © ABB Group November 4, 2013 | Slide 35
- 36. Integration Platform – System 800xA Multisystem Interconnect Subscriber Multisystem Interconnect – System 800xA Power Station - Publisher DC © ABB Group November 4, 2013 | Slide 36 Process Plant – Publisher & Subscriber DC
- 37. Multisystem Interconnect Remote Operations – Logical layout Internet Remote Workplaces Firewall TSG (operations) VSE (services) Domain Application Remote Client Controller(s) Server(s) Server(s) DMZ Remote Workplace Corporate Network Workplaces Firewall Client/Server Network Aspect Server(s) Connectivity Server(s) - Single - 1oo2 - 2oo3 - Single - 1oo2 Firewall Control Network Controllers © ABB Group November 4, 2013 | Slide 37
- 38. Integration Platform – System 800xA Mobilising the workforce • • November 4, 2013 | Slide 38 Connected to all locations • © ABB Group Access to necessary information to solve remote problems Shares information with colleagues
- 39. Integration Platform – System 800xA Cybersecurity Considerations Organization Physical Security Personnel Industrial Access Control Automation Security Administration Compliance © ABB Group November 4, 2013 | Slide 39 & Maintenance
- 40. Remote Access For Maintenance and Diagnostics Maintenance Automation © ABB Group November 4, 2013 | Slide 40
- 41. Remote Access Platform Service Command Centre Mine Conveyor Power Plant Virtual Support Engineer™ Wireless Mesh Network by Site Customer Central Support Team & Vendors MET Plant VPN Secure Clients Mesh Base 2 Mesh Base 1 Center Virtual Support Engineer™ © ABB Group November 4, 2013 | Slide 41 VPN Tunnel Internet
- 42. Remote Access Platform Physical Architecture Virtual Support Engineer™ Java Software Agentless Automated Service Data and Files Collection Command Execution Real Time Diagnosis Proactive Alerts File Transfer Software Updates Security Policy Database Server Full Web UI Application Server External User Communication Server DMZ CRM, ERP, CMDB, Etc. Internet Telnet (CLI) SNMP SSH HTTP FTP Proprietary Local IT Network Devices Database Applications © ABB Group November 4, 2013 | Slide 42 Full Web UI Internal User Virtual Support Engineer™ Virtual Support Engineer™ Communication Outbound ONLY – port 443 SSL Encrypted Certificate Authenticated Polling Customer Site/s
- 43. Remote Access Platform Secure Architecture Light Java Application Agent-less architecture (multi-device, multi protocol) Executes monitoring, collection and command routines © ABB Group November 4, 2013 | Slide 43 Outbound only SSL Encryption End-customer control Audit trail Single view of sites Workflow/User role based Business insight VSE Knowledge development Integrates with existing systems Web-based UI, onsite or hosted
- 44. Future of mining Challenges Ore Extraction Deeper, Steeper, Smarter, Cheaper Material Tracking Systems Automating Yard-Machine Operation Intelligent Tracking and Decision making Stockpile Modeling Simplifying the maintenance tasks Safer, Easier, Faster Remote Control with Intelligent Decisions Remote Control Remote Maintenance Remote Integration © ABB Group November 4, 2013 | Slide 44
Editor's Notes
- #30: Mining Operating Model supported by ISA-S95 and EAOperating Model supports Process, People Collaboration and Technology
- #32: For Substation Automation; AC 800M has today the most powerful implementation of IEC 61850 by support of both OPC and GOOSE for time-critical Power Management applications
- #33: For Process Electrification: AC 800M has full support of integration of Drives, Motor Controllers, Switchgears via Modulbus, Profibus and no also via PROFINET
- #34: For Process Instrumentation:AC 800M has also here full support for integration of instrumentation via Modulbus, HART, Profibus DP/PA and FF H1/HSEFor Safety applications:
- #35: Safety I/O can be connected via optical Modulbus as the slide shows for a F&G and ESD application.For non-SIL application running in the same controller, all other communication protocols are available (with some limitation like FF)
- #36: For Traditional PLCs, DCSsand I/Os:800xA connectivity's are supported for to all traditional DCS system like Advant Master, MOD, Harmony…Special I/O interfaces are also supported for Harmony and AC 800M to almost all our existing I/O systems like S800, S100, S200, TRIO and Satt I/OAnd finally PLC connect can be used for integration of all type of PLCs, either via OPC or via serial communication