Maximising control, visualisation and information at the Mix plant at Lonmin.

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


Mix Concentrator processes► Milling

▪ Raw ore fed into ball mill▪ Diluted with water - Slurry▪ Cyclones separate fine from coarse▪ Coarse returned to mill


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


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




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


Agenda

Benefits of version 3 graphicsBenefits of version 3 graphicsBenefits of version 3 graphicsBenefits of version 3 graphics



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


Superior Graphics

► Enhanced Graphics► Esthetically Pleasing► Realistic Graphics► Air of Professiolism


► Enhanced Graphics

Transparency

Embossed Symbols

Patterns


► Esthetically Pleasing

Lighting Effects

Shaded Tanks

3D Symbols


► Realistic Graphics

Oil Filter

Solenoid Valve

Mill displaying gears

Animated Fan


► Air of Professiolism

HMI Time

PLC Time

Control Logix PLC

Allen Bradley DeviceNet


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:


► Add symbols to template

Popup Graphics

Icon GraphicsGraphic

DescriptionInherited from Master template

Referenced as me.PopUp


► Populate graphics with attributes

Template Attributes

Icon Graphic


► Link popups to icons

Reference Popup Graphic

Icon graphic

Activate as Icon

Show popup on click

Example Popup


Inserting graphics into SCADA is easy

ArchestrA instance

Symbols embedded in instance

Embed ArchestrA Graphic


Inserting graphics into SCADA is easy

Symbol embedded in SCADA


Graphics can be reused

► Another Graphic► The SCADA► Template as embedded graphic

After graphic is created in graphic toolbox it can be reused in:


► Graphic used in another Graphic

Another GraphicAnother Graphic

Graphic from graphic toolbox

Original graphic

Embedded graphic


► Graphic used in the SCADA(Where graphic is not an icon)

Tag entered in Scada



► Graphic used in a template(Graphic becomes an icon)


ArchestrA template

Symbol nameIcon used in

SCADA

Tag already assigned


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


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


The projectThe project


Agenda

ConsiderationsConsiderationsConsiderationsConsiderations


Consideration

► Do not use minimum hardware specifications for GR▪ Might cause instability,▪ Performance issues,

► Network stability▪ Communication failure


BenefitsBenefits

ObjectiveObjective


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



All the slurry pumps need flushing valves

Not Enough space to display flush valves – Need a 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


Technical Challenge

► End result


Completely dynamic popup


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


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



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


Thank you for attendingWonderware User group

Conference 2009

Any Questions?

Maximising control, visualisation and information at the Mix plant at Lonmin.

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Transcript of Maximising control, visualisation and information at the Mix plant at Lonmin.