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

Maximising control, visualisation and information at the Mix plant at Lonmin. Brian Davies Senior Technician Roelf Boshoff SI Engineer. Introduction. The Project. Agenda. Benefits of version 3 graphics. Considerations. Technical Challenges. Introduction to Lonmin.

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

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

  2. Brian Davies Senior Technician Roelf Boshoff SI Engineer

  3. Introduction The Project Agenda Benefits of version 3 graphics Considerations Technical Challenges

  4. Introduction to Lonmin • World’s third largest Platinum producer • Operations based in South Africa • North West • Limpopo

  5. Introduction to Mix Concentrator Mix Concentrator processes • Stock pile and raw ore conveyor system • Raw ore stockpiles • Conveyed to 40 m silos • 4 to 5 grams of PGM's per ton

  6. Introduction to Mix Concentrator Mix Concentrator processes • Milling • Raw ore fed into ball mill • Diluted with water - Slurry • Cyclones separate fine from coarse • Coarse returned to mill

  7. Introduction to Mix Concentrator Mix Concentrator processes • Floatation • Chemicals used to attract PGM’s to bubbles • Primary roughers extract 80-90% • Secondary roughers collect rest • Contaminants removed in cleaning section

  8. Introduction to Mix Concentrator Mix Concentrator processes • Thickener – cone shaped • Feed into centre of cone – 90% of solids • Solids settle to bottom - flocculants • Lighter particles settle on outside – less turbulent • Rake particles to centre at 0.12 RPM • Pumped from centre

  9. Mix Plant Network Topology

  10. Introduction The project Agenda Benefits of version 3 graphics Considerations Technical Challenges

  11. The Project • Replace TI PLCs with Allen-Bradley PLCs • Reprogram PLC code using standard routines made possible by using an Allen-Bradley PLC • Rebuild SCADA using ArchestrA and version 3 graphics • Build a modern looking SCADA • Create a standard graphic library for Mix Concentrator • Establish a system which is easy to expand and change using the ArchestrA architecture

  12. Introduction The project Agenda Benefits of version 3 graphics Considerations Technical Challenges

  13. Benefits of version 3 Graphics Why version 3 graphics? • The superior graphics (Pretty pictures) • Have all the graphics in one place • Inserting graphics into SCADA is easy • Graphics can be reused • Added benefit of connection status indication

  14. Benefits of version 3 Graphics Superior Graphics • Enhanced Graphics • Esthetically Pleasing • Realistic Graphics • Air of Professiolism

  15. Transparency Embossed Symbols Patterns Benefits of version 3 Graphics • Enhanced Graphics

  16. Shaded Tanks Lighting Effects 3D Symbols Benefits of version 3 Graphics • Esthetically Pleasing

  17. Oil Filter Mill displaying gears Solenoid Valve Animated Fan Benefits of version 3 Graphics • Realistic Graphics

  18. HMI Time PLC Time Control Logix PLC Allen Bradley DeviceNet Benefits of version 3 Graphics • Air of Professiolism

  19. Benefits of version 3 Graphics Have all the graphics in one place (Forcing Standards) ArchestrA supplied the means to create Standard Templates With version 3 graphics: • Add symbols to template • Populate graphics with attributes • Link popups to icons

  20. Icon Graphics Graphic Description Inherited from Master template Popup Graphics Referenced as me.PopUp Benefits of version 3 Graphics • Add symbols to template

  21. Icon Graphic Template Attributes Benefits of version 3 Graphics • Populate graphics with attributes

  22. Activate as Icon Icon graphic Show popup on click Example Popup Reference Popup Graphic Benefits of version 3 Graphics • Link popups to icons

  23. Embed ArchestrA Graphic Symbols embedded in instance ArchestrA instance Benefits of version 3 Graphics Inserting graphics into SCADA is easy

  24. Benefits of version 3 Graphics Inserting graphics into SCADA is easy Symbol embedded in SCADA

  25. Benefits of version 3 Graphics Graphics can be reused After graphic is created in graphic toolbox it can be reused in: • Another Graphic • The SCADA • Template as embedded graphic

  26. Graphic from graphic toolbox Original graphic Embedded graphic Benefits of version 3 Graphics • Graphic used in another Graphic Another Graphic Another Graphic

  27. Graphic from graphic toolbox Tag entered in Scada Benefits of version 3 Graphics • Graphic used in the SCADA (Where graphic is not an icon)

  28. Icon used in SCADA Symbol name ArchestrA template Graphic from graphic toolbox Tag already assigned Benefits of version 3 Graphics • Graphic used in a template (Graphic becomes an icon)

  29. Status added to Icon Status indication definitions Add status Indication Benefits of version 3 Graphics Added benefit of connection status indication * Status icon indicates status of the connection to the IO server

  30. Benefits of version 3 Graphics How did version 3 graphics benefit me? • Reduced number of windows to maintain • Reduced development time – More time to focus on optimizing plant • Simplified the development – Any technician can do development • Graphics self-explanatory – Less time needed to train operators

  31. Introduction The project Agenda Benefits of version 3 graphics Considerations Technical Challenges

  32. Consideration • Do not use minimum hardware specifications for GR • Might cause instability, • Performance issues, • Network stability • Communication failure

  33. Introduction Objective Agenda Benefits Considerations Technical Challenges

  34. Flush Valve Suction Valve Delivery Valve Drain Valve Slurry Pump GSW Valve GSW Analog Technical Challenges Flushing Sequence Popup • To clean a pump that carries slurry before stopping and starting • Typical arrangement: * Many different configurations exist

  35. All the slurry pumps need flushing valves Technical Challenges Flushing Sequence Popup Not Enough space to display flush valves – Need a popup

  36. Technical Challenges Flushing Sequence Popup Flush Button Indicating problem in flush sequence Flush Button Opens Flush popup template graphic • 7 valve positions • 3 types of pumps • Analog only constant • 15120 possible configurations

  37. Technical Challenge Flushing Sequence Popup • HOW was it done? • Created a flush template • Popup graphic embedded in template • Populate popup graphic with dummy icons • Define equipment in instance of object • Use OwningObject scripts to assign equipment

  38. Technical Challenge Flushing Sequence Popup • End result Completely dynamic popup

  39. Technical Challenges PLC Layout WHY? Indicate module status Show Inter-PLC communication Fault Finding Grapical devicenet represenation

  40. Technical Challenge PLC Layout • A standard naming convention makes Archestra templates possible • Naming convention example: • Rack R01 • Slot S04 • Slot in a rack: R01S04 • Templates created to assign the IO automatically using the naming convention and containment

  41. Technical Challenge PLC Layout • Templates created and their containment PLC template – assign PLC path Rack Template – module status indication Devicenet template – DNB module CN2DN template Devicenet template – CN2DN module Rack Template • Example Layout of containment: * Contained name very important * PLC path propagated to assign IO

  42. Tags Needed for a single Devicenet Scanner Tags Needed for Slot Status of a single Rack • Tags Needed for: • One PLC • Six Racks • Two Devicenet Scanners Technical Challenge PLC Layout • The OLD method • The NEW method

  43. Technical Challenges Effective alarm annunciation and navigation • Old methods used • Button to open a single alarm list • Indicate last four alams on top menu • 1st stage of new method • Divide alarms into four groups • Add animation to indicate alarms • Navigate to alarm list • 2nd stage of new method • Display critical alarms on top menu • Display mouse-over descriptons • Shown critical alarm count • Add action to navigate to window and popup

  44. Alarm latch in PLC indication Icon indicating alarm (Red) Separate button for reset and acknowledgement Alarm Priority Alarm acknowledgement button Technical Challenges Effective alarm annunciation and navigation BUT With the new and improved system • Alarms can be acknowledged from the popup • Type of alarm and priority also indicated

  45. Technical Challenge Effective alarm annunciation and navigation • HOW was it done? • Create Alarming template • Add attributes to all templates which can alarm • WindowName • AlarmingEnabled • AlarmType • Use Intouch alarm viewer controls to capture alarms • Use owning object scripts to populate graphics • Link windows to alarms

  46. Thank you for attendingWonderware User group Conference 2009Any Questions?

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