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?