Discover what our ABB experts presented at our 2013 mining technology roadshow

1. Llewellyn Best, PAIS, ABB Australia
Future of Mining
Automating Mining Processes
© ABB Group
November 4, 2013 | Slide 1

2. Future of mining
Industry Trends

Increasing focus on automation and autonomy

Increasing focus on leveraging skills through
technology

Unmanned mine operations for safety and
improved productivity

Demand for integrated view of operations I.e.
Remote operations

Standardisation of system for reuse on sites
across the Enterprise

Improved collaboration
© ABB Group
November 4, 2013 | Slide 2

3. Future of mining
Topical Areas
© ABB Group
November 4, 2013 | Slide 3

4. Future of mining
Challenges
? Ore Extraction
? Deeper, Steeper, Smarter, Cheaper
? Material Tracking Systems
? Automating Yard-Machine Operation
? Intelligent Tracking and Decision making
? Stockpile Modeling
? Simplifying the maintenance tasks
? Safer, Easier, Faster
? Remote Control with Intelligent Decisions
? Remote Control
? Remote Maintenance
? Remote Integration
© ABB Group
November 4, 2013 | Slide 4

5. Future of mining
Agenda

Material Handling



Mining Conveyor Control Program
Machine Automation, Material Tracking and Stockyard Management
Remote Access for Maintenance and Diagnostics


Maintenance Automation
Centralised Intelligent Operations

© ABB Group
November 4, 2013 | Slide 5
Multisystem Interconnect

6. Material Handling
Mining Conveyor Control Program
© ABB Group
November 4, 2013 | Slide 6

7. Conveyor Solutions
Traditional Approach


November 4, 2013 | Slide 7
Master drive speed controlled

© ABB Group
Master / Follower
Follower drive(s) torque controlled

8. Conveyor Solutions
MCCP Approach
Torque Ref Drive 1
Speed_Set_Value
RAMP
f(x)
Ramped_Set_Value
Speed Set Value
0%
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
100 %
Speed Drive 1
Speed Dependant Tq
Torque
0%
y1 %
y2 %
y3 %
y4 %
y5 %
y6 %
y7 %
y8 %
y9 %
y10 %
Drive 1
Torque Ref Drive 2
Speed Drive 2
Derivative Torque
Torque Reference
Drive 2
Speed Deviation
PI Control Torque
-
Torque Ref Drive 3
Start-up and
Stop control
Speed Drive 3
Drive 3
E1
Start/Stop
Speed_Average
E2
k
k=4
Average value of measured
speeds from all drives is
measured
Overriding speed control
© ABB Group
November 4, 2013 | Slide 8
Torque Ref Drive 4
Speed Drive 4
Drive 4

9. Conveyor Solutions
MCCP Control

Software package for ACS800 Single Drive or Multi Drive

Running on Drive Control Unit (RDCU)
DDCS

Drive Enable

Start/ Stop

Complete Control
Speed Ref
RDCU
© ABB Group
November 4, 2013 | Slide 9

10. Conveyor Solutions
MCCP Features – Start / Stop Sequence


© ABB Group
November 4, 2013 | Slide 10
Safe Stop and Start Sequences
Safe and Reliable Integrated Brake Control
Safety First!

11. Conveyor Solutions
MCCP Features – Emergency Operation Mode

User friendly Emergency
operation mode
M
3
© ABB Group
November 4, 2013 | Slide 11
M
3
M
3

12. Conveyor Solutions
MCCP Features – Hi-Speed Communication

High speed bi-directional Communication

Accurate load sharing


Feedback of drives used (status, actual
speed, torque)

Cycle time <5ms
Fast control loop for high dynamics and accuracy




DDCS CH2
High speed communication to supervisory system not
required
Minimised motion control logic in supervisory
controller
Less controller performance needed
Fault and Alarm processing

© ABB Group
November 4, 2013 | Slide 12
Shows only required Faults and alarms
DDCS
RDCU

13. Conveyor Solutions
MCCP Benefits

Less supervisory controller capacity needed


November 4, 2013 | Slide 13
Increased Reliability / Decreased Downtime
Reduced Commissioning Time
$$$
Safe and consistent software

© ABB Group
$$$
Easy Conveyor tuning by DriveWindows


Reduced Lead Time and lower cost
Motion monitoring and protection


Maintain existing Site Standards
Lower engineering hours and effort


$$$
Open to every control system


Lower Cost, reduced Complexity
Reduced Training Costs
$$$

14. Material Handling
Yard Machines, Material Tracking & Stockyard
Management
© ABB Group
November 4, 2013 | Slide 14

15. Material Handling
The Aim of Stockyards

Stockyards connecting
consecutive steps in materials
transportation chains with
different time frames

Mixing and blending different
charges to achieve a certain
quality of the outgoing material

Providing a buffer for material
reserve to next continuously
operating processing steps in
the chain.


© ABB Group
November 4, 2013 | Slide 15
One or multiple
inputs, different qualities
One or multiple
outputs, single or different
qualities

16. Material Handling
Machine Automation
Advanced automation / unmanned operation
Area
level
Electrification, instrumentation & automation packages
Train
loading &
unloading
© ABB Group
November 4, 2013 | Slide 16
Belt conveyor
system
Stacker/
reclaimer
Ship loader/
ship unloader
Scanning/
GPS/analyzer

17. Material Handling
Fully Automated Stacking


November 4, 2013 | Slide 17
Stacking exact into the
specified stockpile profile

© ABB Group
Fully automated stacking
assures the execution of
appropriate stacking
method
(Coneshell, Windrow, ..)
Reduced dust by
adjustment of the boom
close to the top of the pile

18. Conveyor Solutions
Fully Automated Reclaiming


Reclaiming also in poor environmental
conditions due to continuously updated
stockpile shape model

Smooth continuous operation reduces
wear and tear

November 4, 2013 | Slide 18
Operation supported by 3D laser
scanner for shape detection and RTKGPS receivers for exact positioning

© ABB Group
Fully automated reclaiming based on
stockpile shape and volume model
Reduction of air digging

19. Material Handling
Machine Tracking and Monitoring / Anti-Collision

GPS / Laser positioning

Calculating and movement
measurement and
prediction

Touch probes
© ABB Group
November 4, 2013 | Slide 19

20. Material Handling
Measurement Integration
Monitors the material flow of bulk material and supplies real time
stockpile tracking by tonnage and grade.


November 4, 2013 | Slide 20
Tracking of materials to the discharge point

© ABB Group
Monitoring of masses/volumes on belt conveyors
Dynamic display of belt load with color differentiation
according material type

21. Material Handling
Automated Routing and Re-Routing
© ABB Group
November 4, 2013 | Slide 21

22. Material Handling
Quality Control


Shows material origin and material owner

Qualities will be tracked, starting at the receiving chute of a
belt conveyor, along the belt conveyor until it was spread onto
the pile or loaded on a train/ship

November 4, 2013 | Slide 22
Laboratory system integration for automated data collection.

© ABB Group
Tracks actual and forecast (planned) material movements
coordinates blending and mixing

23. Material Handling
Visualisation


Virtual stockpiles

November 4, 2013 | Slide 23
Presentation of stored material at its place

© ABB Group
Presentation of all fix assets (belt conveyors distribution
towers) and mobile machines (stacker, reclaimer, ship
loader/unloader)
Block / allocate areas

24. Material Handling
Stockyard Technology Integration
Advanced control
Operating &
dispatching
level
Area
level
Overall plant monitoring
Control of conveyor drive and shifting heads
Calculation of a real time 3D terrain model
Fully automated stacking and reclaiming
Collision avoidance of yard machines between
Material manager
themselves
Collision avoidance of yard machines with piles and
Stockyard management
Stacking/
fixed obstacles
Pile monitoring
Quality
Material
Stacking /
Anti
reclaiming
& visualization management
tracking
reclaiming
collision
technology
& visualization technology
cystem
Data exchange
Electrification, instrumentation and automation
Basic control
Train loading and Machine control and automation loader/
Belt
Stacker/
Ship
Scanning/
local conveyors Stacker/ ship unloader GPS/analyzer
unloading PLC and with operator on the machine
reclaimer
all interlockings and safety features active
reclaimer
© ABB Group
November 4, 2013 | Slide 24

25. Centralised Intelligent Operations
Collaboration Model
© ABB Group
November 4, 2013 | Slide 25

26. Centralised Intelligent Operations
Collaboration Model
Asset Management, Financial Management, HR, ERP Functionality
Mass balancing and production accounting
Material logistics and billing
Data
integration, devi
Mine Planning
ce
integration, mai Predictability, optimization, scheduling
Assay Management
ntenance
Quality Management
Planning and Scheduling
Open, integration of people
Extended Process Control and systemsPCS
Human Resources
Geological
Exploration &
Evaluation
© ABB Group
November 4, 2013 | Slide 26
Mine Plan
Mine
Operation
Energy Resources
ROM
Process
Plant
Product
Stockpiling
Water Resources
Product
Transport
Reclaiming
and
Loading
Shipping
Sales

27. Centralised Intelligent Operations
People, Systems and Equipment Collaboration
© ABB Group
November 4, 2013 | Slide 27

28. Centralised Intelligent Operations
Changing the Way We Operate


One common way to handle
all functions

One common user
language

One way of working

November 4, 2013 | Slide 28
A plant centric view of all
information independent of
system

© ABB Group
Everyone gets the same
view of plant activities
Information sharing without
barriers

29. Centralised Intelligent Operations
Mining Operational model supported by ISA-S95
Collaborate
OIC
ROC
CCR
Monitor &
© ABB Group
November 4, 2013 | Slide 29
Control

30. Integration Platform – System 800xA
Improving Operator Effectiveness…
Documentation
Field Device and
Asset Optimization
History /
Reports
Information Integration
• Predefined process objects
Trends
• Information availability
• Standardized look and feel
• ACL controlled visibility
• Faceplates, Graphic
Symbols
• Alarm management
• Trend, History
• Documentation
Model
Object
Faceplate, Alarms
Graphic & Video
• Device Management
• Asset Monitor, MMS
• Etc….
• Library types
• One change automatically affects
all instances…
ENTERPRISE WIDE!
LICA 101
Control Function
Real Object
© ABB Group
November 4, 2013 | Slide 30

31. Integration Platform – System 800xA
The Power of Integration
Substation Automation
IEC 61850
© ABB Group
November 4, 2013 | Slide 31

32. Integration Platform – System 800xA
The Power of Integration
Process Electrification
Modulebus
PROFIBUS DP
© ABB Group
November 4, 2013 | Slide 32

33. Integration Platform – System 800xA
The Power of Integration
Process Instrumentation
Modulebus
HART
PROFIBUS DP/PA
FOUNDATION Fieldbus
H1/HSE
© ABB Group
November 4, 2013 | Slide 33

34. Integration Platform – System 800xA
The Power of Integration
Safety applications
Modulebus for S800 HI I/O
All other communication for
non-SIL applications
© ABB Group
November 4, 2013 | Slide 34

35. Integration Platform – System 800xA
The Power of Integration
PLC connectivity
PLC Connect
OPC
© ABB Group
November 4, 2013 | Slide 35

36. Integration Platform – System 800xA
Multisystem Interconnect
Subscriber
Multisystem Interconnect – System 800xA
Power Station - Publisher
DC
© ABB Group
November 4, 2013 | Slide 36
Process Plant – Publisher & Subscriber
DC

37. Multisystem Interconnect
Remote Operations – Logical layout
Internet
Remote
Workplaces
Firewall
TSG (operations)
VSE (services)
Domain
Application Remote Client
Controller(s) Server(s)
Server(s)
DMZ
Remote
Workplace
Corporate
Network
Workplaces
Firewall
Client/Server
Network
Aspect
Server(s)
Connectivity
Server(s)
- Single
- 1oo2
- 2oo3
- Single
- 1oo2
Firewall
Control
Network
Controllers
© ABB Group
November 4, 2013 | Slide 37

38. Integration Platform – System 800xA
Mobilising the workforce
•
•
November 4, 2013 | Slide 38
Connected to all
locations
•
© ABB Group
Access to necessary
information to solve
remote problems
Shares information with
colleagues

39. Integration Platform – System 800xA
Cybersecurity Considerations
Organization
Physical
Security
Personnel
Industrial
Access
Control
Automation
Security
Administration
Compliance
© ABB Group
November 4, 2013 | Slide 39
&
Maintenance

40. Remote Access For Maintenance and Diagnostics
Maintenance Automation
© ABB Group
November 4, 2013 | Slide 40

41. Remote Access Platform
Service Command Centre
Mine
Conveyor
Power Plant
Virtual
Support
Engineer™
Wireless Mesh
Network by Site
Customer Central
Support Team & Vendors
MET Plant
VPN Secure
Clients
Mesh Base 2
Mesh Base 1
Center
Virtual
Support
Engineer™
© ABB Group
November 4, 2013 | Slide 41
VPN Tunnel
Internet

42. Remote Access Platform
Physical Architecture
Virtual Support Engineer™
Java Software
Agentless
Automated Service
Data and Files Collection
Command Execution
Real Time Diagnosis
Proactive Alerts
File Transfer
Software Updates
Security Policy
Database
Server
Full Web UI
Application
Server
External User Communication
Server
DMZ
CRM, ERP, CMDB,
Etc.
Internet
Telnet (CLI)
SNMP
SSH
HTTP
FTP
Proprietary
Local IT
Network
Devices
Database
Applications
© ABB Group
November 4, 2013 | Slide 42
Full Web UI Internal User
Virtual
Support
Engineer™
Virtual Support Engineer™
Communication
Outbound ONLY – port
443
SSL Encrypted
Certificate Authenticated
Polling
Customer Site/s

43. Remote Access Platform
Secure Architecture
Light Java Application
Agent-less architecture
(multi-device, multi
protocol)
Executes monitoring, collection and
command routines
© ABB Group
November 4, 2013 | Slide 43
Outbound only
SSL Encryption
End-customer control
Audit trail
Single view of sites
Workflow/User role based
Business insight
VSE Knowledge development
Integrates with existing systems
Web-based UI, onsite or hosted

44. Future of mining
Challenges
Ore Extraction
Deeper, Steeper, Smarter, Cheaper
Material Tracking Systems
Automating Yard-Machine Operation
Intelligent Tracking and Decision
making
Stockpile Modeling
Simplifying the maintenance tasks
Safer, Easier, Faster
Remote Control with Intelligent Decisions
Remote Control
Remote Maintenance
Remote Integration
© ABB Group
November 4, 2013 | Slide 44