7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CIM Distinguished Lecturer Series
Manual Control Process Automation ndash orOperational Performance Excellence
What is the Difference
by Phil Thwaites 2012-2013
(XPS ndash Xstrata wwwmyxpsca)pthwaitesxstratapsca 705-699-3400 x 3463
Introductory RemarkKonigsman (Noranda) - VP Engineering amp Projects
ldquoProcess control is now an essential part of any concentrator operationIt provides a proven vehicle for improving operation economics by
increasing revenues and reducing costsrdquo
ldquoA substantial number of Canadarsquos mineral processing plants have incorporatedthis technology and most have realized impressive returns on investmentrdquo
ldquoThe question one must ask is whether we are tapping the fullpotential of this technology It is the opinion of the MITEC Mineral
Processing Technical Advisory Committee (TAC) that the answer is lsquoNorsquo rdquo
(They saw 2 problem areas 1) small plant amp 2) those plants who use some control but not achieving maxim benefit)
I agree and say we can do MUCH MORE as I will present
Alban Lynch (founder of the Julius Kruttschnitt Mineral Research Centre in Brisbane Australia) in a Oct 2012
correspondencendash ldquoControl is not a high priority here (Australia) even though the effectof inadequate control on the loss of mineral tailings is obviousrdquo
Konigsman 1992 ForewardText Book lsquoA Practical Guide to Process Control in theMinerals Industryrsquo by Flintoff and Mularrsquo
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
Process Automation
Process Automation is understood in a wider sense to include
bull measurement and instrumentation
bull process modelling and simulation
bull process monitoring and data reconciliation
bull data mining and multivariate statistics
bull fault diagnosis and fault tolerant control
bull process control monitoring of product quality amp control performance
bull off-line and on-line process optimisation
bull AI (Artificial Intelligence) methods expert systems neural networks
fuzzy control
bull sequencing
In other words a very large and fascinating field
Ideal for a Control Engineer
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Definition of Process Control(McKee AMIRA P9L) 1997 Review
lsquoProcess control is a broad term which often
means different things to different peoplersquo
Process control is
lsquothe technology required to obtain information in real time
on process behaviour and then use that information tomanipulate process variables with the objective of improving
the (metallurgical) performance of the plantrsquo
Control for the purpose of operations and processimprovement
Process Control Will Not Correct InherentDesign Flowsheet Problems (McKee AMIRA P9L)
lsquoThere is a need to determine and if necessary correct the condition of the plantas a pre-requisite to control development A good example is the importance of
classifier operation and its effect on comminution circuit performancersquo
lsquoTechniques exist (plant sampling modelling and simulation) to audit the actualplant operationrsquo
lsquoCorrecting plant limitations should be seen as a first step in the approachrsquo
eg Co Purification 44 tpd saving $18myr value amp 88-gt95 online time
wwwmyxpsca
XPS Equipment amp Services ndash Process Mineralogy Grp
Correct Plant limitations
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
u n i t s
Process Control ndash XPS
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
As we have practiced for over 3 decades
Poor to Optimized Control
Best Practice
Necessary forlsquoOperationalPerformanceExcellencersquo
1Measure 2Control
3Optimize
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Effect of 115sumpEffect of 115sumpEffect of 115sumpEffect of 115sump
on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)
l i m i t
Process Control Objectives Summary
Management of TOOLS amp RESOURCES to
bull Minimize Process Variation
bull Optimize Process Performance
bull Minimize (Variable) Costs
bull Control Product Quality
bull Maximize Safety
For operational performance excellence ndash ldquowhatever it takesrdquo
Tied to theBusiness
Objectives
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
Process Automation
Process Automation is understood in a wider sense to include
bull measurement and instrumentation
bull process modelling and simulation
bull process monitoring and data reconciliation
bull data mining and multivariate statistics
bull fault diagnosis and fault tolerant control
bull process control monitoring of product quality amp control performance
bull off-line and on-line process optimisation
bull AI (Artificial Intelligence) methods expert systems neural networks
fuzzy control
bull sequencing
In other words a very large and fascinating field
Ideal for a Control Engineer
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Definition of Process Control(McKee AMIRA P9L) 1997 Review
lsquoProcess control is a broad term which often
means different things to different peoplersquo
Process control is
lsquothe technology required to obtain information in real time
on process behaviour and then use that information tomanipulate process variables with the objective of improving
the (metallurgical) performance of the plantrsquo
Control for the purpose of operations and processimprovement
Process Control Will Not Correct InherentDesign Flowsheet Problems (McKee AMIRA P9L)
lsquoThere is a need to determine and if necessary correct the condition of the plantas a pre-requisite to control development A good example is the importance of
classifier operation and its effect on comminution circuit performancersquo
lsquoTechniques exist (plant sampling modelling and simulation) to audit the actualplant operationrsquo
lsquoCorrecting plant limitations should be seen as a first step in the approachrsquo
eg Co Purification 44 tpd saving $18myr value amp 88-gt95 online time
wwwmyxpsca
XPS Equipment amp Services ndash Process Mineralogy Grp
Correct Plant limitations
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
u n i t s
Process Control ndash XPS
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
As we have practiced for over 3 decades
Poor to Optimized Control
Best Practice
Necessary forlsquoOperationalPerformanceExcellencersquo
1Measure 2Control
3Optimize
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Effect of 115sumpEffect of 115sumpEffect of 115sumpEffect of 115sump
on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)
l i m i t
Process Control Objectives Summary
Management of TOOLS amp RESOURCES to
bull Minimize Process Variation
bull Optimize Process Performance
bull Minimize (Variable) Costs
bull Control Product Quality
bull Maximize Safety
For operational performance excellence ndash ldquowhatever it takesrdquo
Tied to theBusiness
Objectives
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Definition of Process Control(McKee AMIRA P9L) 1997 Review
lsquoProcess control is a broad term which often
means different things to different peoplersquo
Process control is
lsquothe technology required to obtain information in real time
on process behaviour and then use that information tomanipulate process variables with the objective of improving
the (metallurgical) performance of the plantrsquo
Control for the purpose of operations and processimprovement
Process Control Will Not Correct InherentDesign Flowsheet Problems (McKee AMIRA P9L)
lsquoThere is a need to determine and if necessary correct the condition of the plantas a pre-requisite to control development A good example is the importance of
classifier operation and its effect on comminution circuit performancersquo
lsquoTechniques exist (plant sampling modelling and simulation) to audit the actualplant operationrsquo
lsquoCorrecting plant limitations should be seen as a first step in the approachrsquo
eg Co Purification 44 tpd saving $18myr value amp 88-gt95 online time
wwwmyxpsca
XPS Equipment amp Services ndash Process Mineralogy Grp
Correct Plant limitations
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
u n i t s
Process Control ndash XPS
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
As we have practiced for over 3 decades
Poor to Optimized Control
Best Practice
Necessary forlsquoOperationalPerformanceExcellencersquo
1Measure 2Control
3Optimize
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Effect of 115sumpEffect of 115sumpEffect of 115sumpEffect of 115sump
on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)
l i m i t
Process Control Objectives Summary
Management of TOOLS amp RESOURCES to
bull Minimize Process Variation
bull Optimize Process Performance
bull Minimize (Variable) Costs
bull Control Product Quality
bull Maximize Safety
For operational performance excellence ndash ldquowhatever it takesrdquo
Tied to theBusiness
Objectives
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
u n i t s
Process Control ndash XPS
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
As we have practiced for over 3 decades
Poor to Optimized Control
Best Practice
Necessary forlsquoOperationalPerformanceExcellencersquo
1Measure 2Control
3Optimize
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Effect of 115sumpEffect of 115sumpEffect of 115sumpEffect of 115sump
on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)
l i m i t
Process Control Objectives Summary
Management of TOOLS amp RESOURCES to
bull Minimize Process Variation
bull Optimize Process Performance
bull Minimize (Variable) Costs
bull Control Product Quality
bull Maximize Safety
For operational performance excellence ndash ldquowhatever it takesrdquo
Tied to theBusiness
Objectives
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Effect of 115sumpEffect of 115sumpEffect of 115sumpEffect of 115sump
on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)on grinding (COFD amp RMF)
l i m i t
Process Control Objectives Summary
Management of TOOLS amp RESOURCES to
bull Minimize Process Variation
bull Optimize Process Performance
bull Minimize (Variable) Costs
bull Control Product Quality
bull Maximize Safety
For operational performance excellence ndash ldquowhatever it takesrdquo
Tied to theBusiness
Objectives
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Simplest of Controllers
hellip we all know
Note No Setpoint or Measurement Shown
Dual Zone ControllerAUTO (or Man)
SPrsquos Frost Warningamp Outside Temp
Note No MeasurementShown
How is Control Applied(in our industry)
bull Mines
bull Ventilation air flow (and pressure) control compressed air and dewatering controls
bull Milling
bull Feed and Tonnage control water ratio control
bull Pumpbox and surge tank controls
bull Cyclone pressure amp density controls
bull Flotation pH air flow amp level controlshellip for Grade Recovery Control
bull Reagent (chemical controls) amp ratio controls hellip for Grade Recovery
bull Thickener bed level flocculant density for clear overflows and final moisture controls
bull Roasting Smelting
bull Feed controls hellip of all feed materials (concentrates fluxes etc)
bull Air flow pressure and temperature controls
bull Power controls hellip ideally as a ratio to feed rate
bull Duct pressure fans blower and acid strength reagent amp quality controls
bull Inventory controls
bull Refining
bull Purification electrolysis chemical and electroplating stripping packaging controls etc etc
hellip predominantly simple regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Layering of Process Control
Field Panel DCS PLC
Instrumentation - Inputs Outputs
Advanced
Regulatory
Manual
PlantOptimization
Optimize
Stabilize
Function Objective
Processes
Optimizing Control
Process
Plant
Optimization
Cash OptimizationEconomics
Site
Loop Control
Measure
EconomicReturn
General Process Control Hierarchy
16
Leveraging Control TechnologyBBA Inc (MRuel)
or Control
ImpactsBusinessProfitability($$)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
ldquoEconomic Benefits of Supervisory Process Control at Kidd CreekrdquoDec 1993 Noranda Technology Conference by P Thwaites J Carriere
bull Hydro Management amp Site Peak Control Objectivesbull Improve knowledge amp awareness of power costs
bull Improve amp stabilize SITE power control (at approx 133 MW of power consumption)
bull Control the lsquodailyrsquo Peak load and shift power consumption to lsquoOff Peakrsquo while maintaining production
bull Using 3 zinc plating rectifiers at approx 22 MW maximum power each
bull Results
1 Lowest overall (ckWh) Ontario Hydro Mining customer using TOU (time ofuse) Hydro rates
2 Cumulative (5 year) total savings from 1989 to 1993 incl = $176000001 1989 = $20M saving on 1089851 MWh
2 1990 = $24M
3 1991 = $35M
4 1992 = $56M
5 1993 = $41M saving on 1076755 MWh
bull Conclusions1 There are MANY more OPPORTUNITIES throughout
the Metallurgical processes for supervisory control
ldquo APC can have considerable returns
hellip to help the Businessrdquo
Hydro Management ampSite Peak Power Control
Importance of Control Performance
EMERSON Global Users Exchange (2007)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control System Loop Diagnostics (eg ABB)
Diagnostic Conditions Monitored are
bull Final Control Element (FCE) Stiction
Size amp Leakage
bull Excessive FCE Action
bull Tuning Problem
bull Loop Oscillations
bull External Disturbances
bull Loop Nonlinearity
bull Data Reliability
bull Insufficient Travel
bull No Response to Signal Change
bull Noisy or Unstable Outputbull Sluggish Response
bull Valve BodySeat Wear
Diagnostics hellip are you using them
5 Essential Control Loop Elements (D Harrold)
amp lsquoConsider the Whole Looprsquo (Forsman ABB)
ABBABB Corporate ResearchK Forsman 1998 No 10
Consider the whole loop
PC-program in
Advant OCS
DA
IP
Positioner
FT
AD
Deadband
Filter
Ramp rate Filter
Actuator
Filter
3-15 psi
0-6 bar
4-20 mA
4-20 mA
mV
Five EssentialControl Loop Elements
1 Sensing element2 Transmitter3 Controller4 Final Control Element
(eg Actuator or VSD)
5 Process
Only when all five elements are performing at their bestwill the control system meetexpectations
February 1999 ndash CONTROL ENGINEERINGby Dave Harrold
1
2
3
4
5 Process
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Importance of Regulatory Loop Tuning(Flotation air flow loop)
Retuned Old to New hellipPoor to Improved prior to Optimized
Process Control Improvements - PrimaryGrinding Circuit
With proper filtering amp
tuning
Standard Dev
50rarr14 th
0
2
4
6
8
10
12
14
16
18
20
983085 1 0 5 983085 9
0 983085 7 5 983085 6
0 983085 4
5 983085 3
0 983085 1
5 0 1 5 3 0 4 5 6 0 7 5 9 0
Bins 983085 Feed Rate Set983085Point Deviation
F r e q u e n c y ( )
BEFORE
AFTER
STD=14 th
STD=50 th
72 reduction of
standard variation
Primary Feed Tonnage
Reduction 72
hellip regulatory control
Note we normally ratio Mill water to feedrate
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1531
11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Process Control Improvements - PrimaryGrinding Circuit
Benefits rougher feed density
Standard Dev
0017rarr0007 kgl
Mill Discharge Water Addition
Reduction 5800
20
40
60
80
100
120
140
160
180
200
983085 0 0 5
983085 0 0 4
983085 0 0 3
983085 0 0 2
983085 0 0 1 0 0 0 1
0 0 2 0 0 3
0 0 4 0 0 5
Bins 983085 Primary Rougher Feed Density Set983085Point Deviation
F r e q u e n c y
BEFORE
AFTER58 reduction of
standard deviation
STD=0007
STD=0017
hellip regulatory control
Eland Mill (2010) Overall Recovery Improvement fromPrimary Grind amp Primary Rougher Recovery Improvements
1) Prim Grind Improvement
Before
42 -75microns
After
52 -75microns30
35
40
45
50
55
Before After
Before
After
2) Primary Rougher
Recovery Improvement
Before
60
After
73
30
35
40
45
50
55
60
65
70
75
Before After
Before
After
On a feed grade of
254 gt PGE
bull Sec roughertails dropped
024 gt
bull Overall plantrec increased
3
bull Finalconcentrate
grade increasedby 10 gt
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
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11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1531
11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1331
11020
Control Loop Improvement(Flotation level controller)
Several loops were updated
Typical results
bull Reduction of variability
bull Elimination of bias
ndash lsquovirtual absence of Integralactionrsquo
bull Smoother control action
bull KPIrsquos (key performance
indicators) at target00
50
100
150
200
250
98308530 98308525 98308520 98308515 98308510 9830855 0 5
Bins 983085 106B Level Set983085Point Deviations (LIC9830853506)
F r e q u e n c y
BEFORE
AFTER
STD DEV 27
STD DEV 60
56 Reduction of STD deviation
100 Reduction of average deviation
Bias elimination
Flotation Cell Level Control
Reduction 56 ampBias Elimination
hellip regulatory control bias removal
Column Flotation - Feed Control
After STD=314 m3 h
Before STD=754 m3 h
Objective1 More flexibility2 Increased feed stability
Feed VariabilityReduction 58
Feed variability reduction (of 58)then correlated to concentrategrade variability reductionbull 79 (std dev) reduction
for the column Ni (impurity)
in Cu concentrate grade
hellip regulatory control
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1431
11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1531
11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1431
11020
Control Tuning Summary
ldquoProper controller tuning is the largest quickest and leastexpensive improvement one can make in the basic
control system to decrease process variability rdquo
ndash TL Blevins GK McMillan WK Wojsznis MW Brown Advanced Control Unleashed ISAPress Research Triangle Park NC 2003
------------------------------
Donrsquot underestimate the impact
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo ndash Operational Performance Excellence
bull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for Your Plants to Consider
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1531
11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1531
11020
Automation is hellip
1 the technique method or system of operating or
controlling a process by highly automatic means
reducing human intervention to a minimum
2 a mechanical device operated electronically
that functions automatically without continuous inputfrom an operator
3 act or process of automating
4 the state of being automated
Ref Dictionarycom
Automation ndash How Do We Apply It
bull Can be done on various platforms (PLC or DCS) on specific process unitsor areas of the Plant
bull While I am aware of fully automated unmanned (Hydro) generation stations (turbines) ndash egSandy Falls (Timmins) where the process is simple we do not know of a fully automatedMill But recently PYROGENESIS (GH) reported on their lsquoPlasma Arc Waste DestructionSystemrsquo for the US Navy Carrier Marine vessels amp mobile units ndash a fully automated process
bull Some Automation examples we see
bull Motor starts and stops eg crushing plants and sump pump controls
bull Remote starts start-up and shutdown sequences which can be quitecomplex
bull Mill lube systems Conveyor belt material handling systems
bull Mine Drilling equipment and (Mine) Autonomous haulagebull ldquoVale puts Railveyor to testrdquo ndash Sudbury Mining Solutions Journal Sept 1st 2012
bull ldquoA key pillar of Riorsquos mine automation initiative is autonomous (vehicle) haulagerdquo -Technology Case Study Rio Tinto Mining People amp the Environment Jan 2012
bull Pressure filtration amp Batch processes
bull Automated metal (plate) stripping as we use for Ni Cu amp Zn stripping
helliphellip etc etc
Ensures steps are not missedprotects assets amp improves safety
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1631
11020
Advanced Process Control (APC)
bull ldquoIn terms of automation functionality regulatory control and APC serve much differentpurposesrdquo
bull ldquoThe primary role of regulatory control is to ensure stable safe and reliableoperations while maintaining process units at a desired or specified condition Itdoes not attempt to continuously improve operations in an economically optimalmannerrdquo
bull ldquoAPC on the other hand is a supervisory control application that coordinates alarge number of parameters to maintain control closer to operating constraints andmore favorable economic operating conditionsrdquo
Eg
bull Roaster Control ndash Layered MPC (Model Based Control with optimization logic) ontop of well tuned PID mass feed controllers
bull Results
1 77 reduction in bed temperature Stnd Dev allowing temperature andthroughput optimization closer to Roaster constraints
2 Overall throughput increase over extended periods of 4
Implemented Multivariable Predictive Control
Approx 230 known MPC applications hellip all vendorsof these installations 70 Honeywell B Jonas
Note In mining (mineral processing) excludes cement steel
Crushing
SAGAG Mills
BallRod Mills
Flotation
CCD Thickeners
Roaster
Induration
EAF
Converter
Acid Plant
SX
Alum Autoclaves
FiltrationEvaporation
Heat Interchange
Precipitation
Calciner
Kiln
Other
MPC in Mining All Vendors (Over 230 Units Controlled)
T
T
T
TT
T
T=Train
Alumina
Cu Ni ZiUr Au
T
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1731
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1831
11020
Process Instrumentation
IndustrialCommunication
Process Analytics Factory Sensors
Continuous Gas Analyzer In Si tu Gas Analyzer
Natural Gas Analyser (CV)Kiln Sampling Probe
ProximitySwitches
Fail SafeSensors
Code ReadingVision Sensors
RFIDSystems
CommunicationProcessors PLC PC
SecurityProducts
IndustrialWLAN
Industrial
NetworkSwitches
Level Weighing
Flow Valve positioner
Pressure
Siemens Sensors amp CommunicationComprehensive Product Portfolio for us
Processprotection
Temperature
S Shephard - Solutions for the Mining Industry
E+H Instrumentation for the Mining amp MetalsIndustry
pH lsquobestpracticesrsquoExample
E+HCanada
Slide16
Digital pH sensors with Memosens
Memosens with inductive datatransmission eliminates problemsbased on
Corrosion
Contacting problems
Salt bridges
Moisture
Leakages
High impedance connection
Ground loops
Safe connectorsystem
Dirty connectionsare irrelevent
17 units = 70 savings at MineraLos Pelambres - Chile CPF81D + CM42
E+H C anada
Slide 1
MemosensLiquiline
Digital pH Systemsndash Maximize process up-time
2011 Xstrata forbull Antapaccay Mill (Peru)
bull Las Bambas Mill (Peru)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 1931
11020
EampH Typical positioning of a thickenerscritical parameter measurement devices
S Rigling ndash E+H Australia
E+H Combined Technologies ndash Instrumentation Solutions for our Industry
Radar amp Capacitance Level
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2031
11020
Flow Measurement ndash Cidra SONAR
SONARSONAR ndashndash A New Class of Meters with Distinct Application Advantages A New Class of Meters with Distinct Application Advantages
SONAR
VOLUMETRIC FLOW METERS
Ultrasonic
Coriolis
Vortex
MultivariableDP
Magmeter
Ref Christian OrsquoKeefecokeefecidracom
Hydrocylone feed line ndash as used by Collahuasi
Xstrata Cu - StandardConcentrator (5)Antapaccay Las Bambasselected SONARtrac for theprincipal slurry lines
Flow Measurement - In Circuit
Platinum 2012Platinum 2012 The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator The Impact of Entrained Air and Enhanced Flow Measurements at the Eland Concentrator
SONAR
VOLUMETRIC FLOW METER
Ref Christian OrsquoKeefe cokeefecidracomFelix Peacock Huysamen Thwaites
ldquoYour accurate flow measurements are helping us with flotation control
bull We have automated mass pull control across the cleaner sectionbull Our next phase is utilising the Level controllers Flow Optimiser
Analyser amp Cidra meters to implement our advanced flotation controlrdquo Buang Moloto (Eland ndashXstrata Alloys)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2131
11020
Online Mineral Particle Size Measurement ndash OPUS Andrew Smith Sympatec GmbH AUTOMINING 2010
Full particle size distributionbull from 1 micron on flows lt 15 ms
Ultrasonic Extinction for real timeMeasurement helliphellip
bull Moisture content is determined bymeasuring the effect on a microwavesignal being passed through
bull The emitted signal passes through(Ore or Concentrate) and is detectedby a receiving antenna
bull The microwave signal interacts withany moisture in the process materialDegree of interaction is measured andused to derive a moisture value
bull An ultrasonic level sensor alsomeasures the amount of material onthe belt and this is factored in
bull Accuracy 05 ndash 1
bull Range 1 ndash 90 moisture
PC Group Review Meeting 13th Dec 2012
TransmittingAntenna
ReceivingAntenna
Online Moisture Analysis - MicrowaveMoistScan reg - Real Time Instruments Aus
Strathcona Mill (amp Xstrata Cu Mt Isa Mine Australia)Supported by Bondfield Group North Bay
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2231
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2331
11020
ldquoIn an ideal situation collectors should absorb selectively on thevaluable minerals and depressants should absorb selectivelyon the unwanted gangue mineralsrdquo
ldquoUnfortunately this is almost never the case and the rightcombination of collectors amp depressants
bull requires the development of dedicated chemicals
bull a lot of fine-tuning in the flotation processrdquo
So what are the components forOperational Performance Excellence in flotation
Flotationhellip ref Akzo Nobel - Cellulosic Specialties (Depramin gangue depressants)
Components forOperational Performance Excellence
Flotation Objective
1 Always Prevent Flooding hellip or empty banks amp
2 Maintain an Accurate responsive Pulp Level on a second basis thereby allowing control of the setpoint
Note pulp level is the variable known to the Operator
and is correlated to mass pull and recovery
One is Pulp Level hellip
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2431
11020
- implement quick access to floats
- Cleaning water to rod
Level measurement Access to floats yes important
No access to clean floats- Build up on floats- Inaccurate reading
XPSFloattradeFlotation level measurement
Flotation Level Control -Best Practice Example
1 Basic Level Device2 Level Control
Tuning (PID
Feedback)
5 Level Control Tuning(+ Feedforward)
4 Smart
Positioner(Valve
opening
Feedback)
3 Split Range
Actuation(2 Dart Valves)
8 Best Practices ndash
Control to Metallurgy ($$) Flotation
Level Control
6 Surge Tank
ControlTuning
7 Level Setpoint
Optimization
(eg FrothVelocity
Controller)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2531
11020
Flotation Control Points on ControlStructure and importance of layering (Gilles)
Flow Control
MetallurgicalControl
Ratio Control
Set Pointccmin
MeasurementTonnage orTonnageHead Grade
Set PointGramTon
Measurement(Tail or ConcAssay)
Set PointOperator Recovery orGrade Target
All of the Met Loops are PIPID controllers for supportability
If problems occur operators may turn off one level of control ata time Independently for each reagent
Use standardratio blocksto ensure youcan layer ontop anotherlevel of control
Flotation Reagent Control -Best Practice Example
1 Basic MeasurementMag meter or Coriolisor pulsed device
3 Flow Controltuning (engUnits)
Robust Reagent Control(Feedforward only)
5 Met Control(Ratio) GMUgMetal Unit
4 Ratio ControlgTonne
7 Met Controlwith feedback Optimization (Mass PullAnalyzerrecovery orfroth quality)
8 Best PracticesFlotation reagent Control
=gt Optimum Metallurgy ($$)+ 25 lower reagent costs
2 Specialty(pure undiluted)
collectors
6 Met Controlwith strategies for start-up shutdownamp short stoppagesor losses in XRFdata
Metallurgical (Met) Control is the goal
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2631
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Process (amp Plant) MonitoringOSIsoft PI System 2010
Used extensively by Xstrata
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2731
11020
Measure Control OptimizeFlotation Control Best Practices
S t a g e
1
S t a g e 2
S t a b i l i z a t i on
S u s t a i n e d V a r i a b i l i t y R e d u c t i o n
S t a
g e
3
O p t i m i z a
t i o n
Flotation Control
Stabilization
to
Optimization7
u n i t s
Process Control
Control Optimize
poor control better control
higher production
lower costs
setpoint
Process constraint
best control
time
Measure
Sustaining the gains
Control Performance Monitor (CPM)
Control Performance Monitor (CPM)MatrikonHoneywell ishellip
Plant Control
a control performance improvement product thatcan diagnose causes of poor control at all levels ofthe plant control hierarchy
Advanced Process Control
Analyzers amp OnlineInferentials
Regulatory Control
Instrumentation Layer
CPM can enable a sustainable workflow that enables tracking of maintenance efforts as well asarchiving maintenance history on each loop
bull MONITORS advanced control assets for poorperformance amp provides detailed diagnoses
bull PROVIDES TOOLS detecting instrumentfreezes data spikes rate of change alarms andhigh-low limit violations
bull MONITORS regulatory control assets for poor
performance amp provides detailed diagnoses
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2831
11020
1st (of 150) CPM Controller ndash Strathcona Mill
Motivation Continuous monitoring prioritization of process variability for Sustained Variability Reduction
Continuous monitoring of controller service factors ( ie Manual or Auto how the controllerperforms etc )
Indication of the root cause of deteriorating controller performance
View all area controls
Report results for
Managers
Supervisors
Technical staff
also utilized at Raglan ampEland Platinum Mills
How we should use CPM
983120983126
983124983145983149983141
983120983126
983124983145983149983141
983117983137983150983157983137983148
983108983137983145983148983161983127983141983141983147983148983161
983108983137983145983148983161
983122983141983153983157983145983154983141983155
983105983156983156983141983150983156983145983151983150983105983155983155983141983155983155
983120983154983151983138983148983141983149
983127983119
983120983141983150983140983145983150983143
983122983141983155983151983148983158983141983140 983108983145983155983152983151983155983145983156983145983151983150
983127983151983154983147983142983148983151983159
bull CPM providesassessment notification
bull User needs to take actionfix the problem
bull Move loops with knownissue to anotherdisposition category
bull Donrsquot be nagged on thesame problem again
983107983120983117
983107983144983137983149983152983145983151983150
Sustained Variability Reduction CPM trial at StrathconaMill
Xing Jin (XPS Control Engineer)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 2931
11020
Manual Control Process Automation ndash or OperationalPerformance Excellence What is the difference
Discussion topics will include ndash Control Engineering as applied to Process Control
bull Process Variability Control amp Process Optimization
bull Control Solutions from Manual control amp operation
bull Control Loop Applications amp Tuning Impacts
bull The Technology Some Important Aspects System Selection
bull Automation and Advanced Control
ndash Elements Necessary for Success
ndash Instrumentation Solutions hellip lsquoTo Be Aware ofrsquo
ndash Operational Performance Excellencebull Examples selected are Flotation Level Control Reagent Control
ndash Asset and Performance Monitoring
ndash Opportunities hellip for You and for your Plants to Consider
Perceptive Engineeringrsquos Focus Vision(Dr D Sandoz DJ Lovett)
Optimisation
amp Scheduling
Advanced Process
Control
Conventional
Regulatory Controls
Management
Information Systems
Intelligent
amp ldquoSoftrdquo Sensors
Conventional Sensors amp Instrumentation
Operating Constraints
Valve position
Setpoints
Performance Reports
Operating Plans
0 20 40 60 80 100 1 20 140 160 1800
5
10
15
20
25
30
35
40
Time
S P E
SPE
ConfidenceLimit
Early Warning Process
Condition Monitors
Classification forQuality Control
0 20 40 60 80 100 12010
15
20
25
30
35
40
Sample No
F e O
Soft Sensors
Integrated Condition Monitoring and Advanced Process Control
Control System
Integration
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3031
11020
CMP 2010 PAPER CMP 2010 PAPER 2727 byby
Kairos Mining (Chile) ndash A ComprehensiveApproach to Sustained Benefits in Automation
TESTING LABORATORY
TRAINING CENTER
KAIROS REMOTE SUPPORT CENTER
REMOTE MONITORING amp SUPPORT CENTER
DATACENTER
Giselle Schifferli
Opportunities helliphellip for You and OperatingPlants to consider hellip
For Plant Operators ndash Is your feed stable ndash Are your instruments calibrated and performing ndash Are you aware of wireless instruments (including vibration) ndash Is your control system up to date and stable ndash Are you in manual or auto control ndash Are your Operators acting on alarms or are they nuisance ndash Do you understand and accept your process variability ndash Are you operating within the design targets and process constraints
bull (pumps cyclones supplies thickeners roasters furnaces etc etc)
ndash Are you using your surge capacity hellip or running tight level control ndash Are you at optimum and are the controls robust ndash Are you benefiting from asset management systems ndash Are failure fault detection systems implemented ndash Can you make the same product for less energy or material consumption ndash Do you Operate with or without a Control Engineer
ndash Does your Plant Process or Processes run as well as your car
We can do Much More and be Much More Efficient
lsquoOperational Performance Excellencersquorequires a solid performance of theregulatory layer AND process optimization
(P Thwaites AUTOMINING2008 Plenary lecture ChileCMP 2013 Plenary lecture CIM DL Series 2012-13)
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
7212019 DL_CIM PT Process Control Lecture 2013-01-24 Rev0 [40 Mins] - CMP2013 2nd Plenary
httpslidepdfcomreaderfulldlcim-pt-process-control-lecture-2013-01-24-rev0-40-mins-cmp2013-2nd 3131
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