Volcan Mining Company: PlantPAx System Allows For Inter-mine Communication and Leads to Decreased...

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Carlos Diaz - Project Manager

Control System Integration SAC (Process RcSI)

Jorge Oviedo – Automation Project Manager

Volcan Compañia Minera SAA (End user)

PlantPAx on Silver Oxides Leaching Plant


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Agenda

Project Summary and Conclusions

PlantPAX application – Eng Review – Proposal – System Development

Silver Oxides Project – Development and Startup

Volcan Mining Company

Control System Integration SAC (RcSI)


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All operations are over

4300 mosl (14000 fosl)


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Production – World production ranking

Silver (metal) – Silver, Copper, Zinc, Lead (concentrate) 5th World largest producer of zinc (2th of Perú) 7th World largest producer of silver (1st of Perú) 8th World largest producer of lead (1st of Perú)

Mining Units

Yauli – Chungar – Cerro de Pasco – Alpamarca 10 Underground Mines – 7 Concentrator Plants – 1 Leaching Plant All Mining Unit are located over 4300 mosl (14,000 fosl) 352,000 hectares of concessions More than 70 years of operations


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Some mines are more than

1200 meters deep and

contain 23 km of tunnels

Man power

2500 direct workers 1500 indirect workers

2013 Production

279,600 TM Zinc 67,400 TM Lead 20,7 Millions Oz Silver

34 years of reserves


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Agenda

Final Project Statistics and Conclusions






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Silver Oxides Project

Main Data

A green field project – 2500 mtpd – Next expansion 4000 mtpd 235 million dollar investment 13 years project lifetime

Main process

Crushing plant (Primary – Secondary – Tertiary) with close classification circuit – Washing plant (To remove fine material)

Bars and balls mill section (With close semiautomatic classification) Leaching in stirred tanks (48 hours residence time) CCD’s (counter current decantation) in three stages Merrill Crowe process – Smelter Filters plant – Cyanide destruction plant – Lime Plant


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Control Platform Selection

Main considerations Mining market presence in Peru

Local support and many solution providers

Easy to learn and operate platform (intuitive to the end user)

Prestigious worldwide brand

Technical Considerations Redundancy required – Processors – Communications – Power Supplies –

Servers

A Scalable Platform with efficient licensing

Multiple communication protocols for Instrumentation and Vendor equipment

Managed Switches

Easy Integration with CISCO corporate Systems


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Control Platform Definition

Solutions and Systems Evaluated Rockwell Automation

Siemens

ABB

Invensys Foxboro

Emerson

Schneider

Other Considerations Previous experience of Vendor in Silver / Gold Leaching Plants

Previous installations in Volcan Mining Company

Trained personnel In House


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Project Development and Startup

Main challenges during commissioning and Startup

Integration of Schneider MCC’s (Ethernet ModBus TCP/IP) Integration of Instrumentation (Foundation Fieldbus) Integration of Vendor Pumps (Profibus DP) Integration of many Vendors (EtherNet/IP)

Pre-commissioning include testing

Controllers in plant Remote I/O cabinets and signals (EtherNet/IP) Remote I/O from other vendors (Profibus DP) Digital instruments (Crushing plant) Instrument Protocols


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Issues during commissioning

Time response in MCC’s (Ethernet ModBus TCP/IP) Number of nodes in each Modbus master Percentage of load in main processors, because of integration of

many Vendors (Divide programs in two controllers) Testing redundancy in application servers Changes in Supervisory System (HMI) (Vendor integration) Integration and performance in Vendor applications Integration and monitoring of power systems data Networking integration and testing


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Agenda







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Control System Integration S.A.C.

Peruvian company dedicated to develop industrial automation solutions

according to customer requirements in control, process, motion and

information areas, integrating RA hardware & software + engineering

services + Encompass and third parties.

More than...

14 years in local automation market 200 successful projects 20 years using RA products

RA Certified Recognized System Integrator:

Control & Process. Information (in progress) Major vertical markets: Mining, Food, Chemical


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Agenda







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Project Engineering Review

External engineering company

Buenaventura Ingenieros S.A. (Peru) SNC Lavalin (Peru office)

Engineering documents from customer

Control System Architecture Control System Technical Specification Control System Datasheets P&IDs Equipment list

Instruments and motors

I/O List Loop diagrams One-line electric diagrams


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Key control requirements from customer

Distributed Control System Redundant Controllers and Power Supplies

Remote I/O included

Foundation Fieldbus for instrumentation Integration with vendor packages

Vendor control system must be based on Allen Bradley controllers with

EtherNet/IP communication

Integration with Motor Control Centers

Ethernet communication protocol

Redundant or Fault Tolerant communication infrastructure for all field buses


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Key IT requirements from customer

Redundant or Fault Tolerant communication infrastructure for all field buses

All main communications will be EtherNet / IP Control System and Motor Control Centers

All switches must be layer 2 (managed) All twisted pair copper connections must be Cat6A Client/Server application software Process data historical server Web based reporting system KVM extenders for all workstations Use customer’s standard brands (if possible)


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Standards from customer

IBM for rack servers SystemX 3650 M4

IBM for server cabinets Enterprise model

Lenovo for operation and engineering workstations Dual 24” LCD monitors – Full HD

Panduit for fiber optics (cables & accessories) Single mode 24 fibers – LC connectors

Cisco for distribution switches and routers IE-3010 model

Cat 6A for EtherNet communications


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PlantPAx Control System Proposal

Rockwell PlantPAx as DCS solution

Sized with PlantPAx Estimator (IAB) Based on redundant processors Based on PlantPAx software platform

Redundant HMI/Data Servers

Redundant Historian Servers

Web reports

Asset Management (optional)

Remote visualization (optional)

Function blocks & faceplates PlantPAx 2.0 library

Fieldbus & third-parties protocols integration


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Integration

EtherNet/IP for vendor packages Easy Encompass and Vendor Packages

integration

Rockwell Automation: Stratix 8000 switches for access level

EtherNet/IP to Foundation Fieldbus H1

gateway with accessories for

redundancy

Prosoft-Technology for third-party protocols:

ModbusTCP, Industrial EtherNet,

ProfibusDP

E+H for FF H1 instrumentation


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Others providers

Hoffman enclosures Nema 12 & 4X

Panduit fiber optic Path panels (rack & panel mount)

Patch cords & accessories

CISCO switches and routers

IBM Servers & communication cabinets

Lenovo workstations Black Box

KVM switch & extenders


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PlantPAx Control System Control Cabinets

Control Cabinets

Inside electrical rooms

Nema12 / IP55

All Allen Bradley marshaling

Terminal blocks, circuit breakers, power supplies, etc.

Network infrastructure

Access switches Fiber optic patch panel


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PlantPAx Control System Field Cabinets

Fields Cabinets

Field installation

Nema4X (stainless steel)

All Allen Bradley marshaling

Terminal blocks, circuit breakers, power supplies, etc.

Network infrastructure

Fieldbus gateways Access switches Fiber optic patch panel


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Control Cabinets (locally)

Device Level Ring (DLR) topology w/STP cable (fault toulerant)

Between Control Cabinets and Remote I/O

Cabinets

REP Fiber Optic SingleMode ring topology (fault toulerant)

Between Control Cabinets and Control

Room

Fiber Optic SingleMode start topology

Vendor packages have independent network

(router for interconnection)

PlantPAx Control System EtherNet Network


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PlantPAx Control System Control Room

IBM Servers

(5) SystemX 3650 M4

Lenovo Workstations

(4) ThinkStation S30 3 OWS + 1 EWS

Panduit fiber optic accesories

Distribution switches

Cisco IE3010 Layer 2 and 3|


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PlantPAx Control System Control System Architecture


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PlantPAx Control System HMI Supervisory Application


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PlantPAx Control System HMI - Crushing


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PlantPAx Control System HMI - Grinding


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PlantPAx Control System HMI - Cyanidation


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PlantPAx Control System HMI - Clarification


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PlantPAx Control System HMI – Reagent Dosing


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PlantPAx Control System HMI – Area Overviews


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PlantPAx Control System HMI – Trending


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PlantPAx Control System HMI – Valve Faceplate


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PlantPAx Control System HMI – FVNR Motor Faceplate


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PlantPAx Control System HMI – VFD Faceplate


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PlantPAx Control System HMI – Analog & PID Faceplates


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PlantPAx Control System HMI – System Health


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Plant Network Distribution


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Corporate Network Monitoring

24 hour x 7 days monitoring


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Agenda







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Project Summary

Controllers:

3 Redundant pair of ControlLogix processor 1200 wired I/O 3000 communication I/O

EtherNet

300 EtherNet nodes 280 nodes for control

20 nodes for infrastructure

Foundation Fieldbus:

+180 instruments in 25 FF H1 redundant rings Level, Pressure, Flow, pH, ORP, density

Valve digital positioners


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Project Summary

Motor Control Centers

+250 motors in 50 MCC columns distributed in 4 electrical rooms

Vendor Packages:

+16 different providers for all type of sub systems. In example: Metso (mill & lubrication system)

Prominent (reagent dosing)

FLSmidth (filters)

Cyanco (Cianide preparation)

Tecpromin (Lime plant)


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Conclusions

The technical proposal from Rockwell Automation presented by RcSI included all that was expected as end user

We got communication with all Instrumentation, Vendor equipment and MCC’s in the plant

PlantPAx allowed us to expand the system and solve the problems in a short period of time

For the next expansion the System is ready to include more signals and MCC’s

With Rockwell Automation we got exactly what we wanted

The PreComm and Startup time was 5 weeks shorter than expected


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Questions

Carlos Diaz - Project Manager

Control System Integration SAC (Process RcSI)

Jorge Oviedo – Automation Project Manager

Volcan Compañia Minera SAA (End user)

Volcan Mining Company: PlantPAx System Allows For Inter-mine Communication and Leads to Decreased...

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