PES: An Innovative Approach to Process Control Systems (and Energy Management) for Mining
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Process control technologies have evolved over the years to meet the ever-changing demands of mining operations caused by factors ranging from grade decline to strict regulations as well as the changing workforce. The next step in this evolution needs to address this new reality where engineering efficiency and process optimization are a must, while also adding further efficiencies and visibility into energy usage and spend. PlantStruxure PES (Process Expert System) is the next generation Process Automation Systems developed to address the ever increasing demands and constrains of today’s mining and mineral processing operations. This presentation explores… § The integration control and power - making energy as an active part of the process § How PlantStruxure PES helps to streamline the engineering development for new mines or expansions § A single and simple environment - making operation and maintenance easier § A preview of the software that’s the foundation of the system
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PES: An Innovative Approach to Process Control Systems (and Energy Management) for Mining
- 1. PES: An Innovative Approach to Process Control Systems (and Energy Management) for Mining Mining Metals and Minerals competency center
- 2. ● Workforce crisis ● Skills shortage ● Minerals scarcity ● Extreme mining ● Grade decline Key Trends in Mining In mining, energy can be up to 40% of the total cost of its supplies
- 3. By 2013, the demand for mining engineers is expected to exceed supply by Talent Strategy Advisors
- 4. Implications of Trends and Needs ●Less funds available ●Reduced workforce (less resources to develop in-house solutions or no core activities) ●Need to produce more with less ●Minimize design time ●Optimize project cost ●Operating cost reduction ●Maintenance cost reduction
- 6. Hybrid Process Mining Metals Cement F&B The Conventional Solutions Continuous Process Oil Chemicals Power Manufacturing Automotive Machinery Complex Process Loops Hi-Availability Process Language Discreet Interlocking Electrician Language Distributed Control (DCS) Programmable Controller (PLC)
- 7. Industry Answer? Distributed Control (DCS) ? Programmable Controller (PLC) ? Hybrid Control System (HCS)? Process Automation Controller (PAC)? Collaborative Automation Systems?
- 8. ●Simple to: ●Design ●Operate ●Maintain ● Troubleshooting ●Remote access ●Intuitive ●Simple to modify, improve and expand ●Reuse ●Online changes ●Future proof technologies ●Easy interaction with other systems (MES/Energy/Instruments) Users need a system...
- 9. ...that represents a real application CrushingCrushing MillMill FlotationFlotation Homogenization Yard / Stacking Homogenization Yard / Stacking Water TreatmentWater Treatment Products YardProducts Yard Schneider MineSchneider Mine ReclaimingReclaiming
- 10. CrushingCrushing MillMill FlotationFlotation Homogenization Yard / Stacking Homogenization Yard / Stacking Water TreatmentWater Treatment ReclaimingReclaiming Products YardProducts Yard Schneider MineSchneider Mine
- 11. The System Translates Each Mining Operation P&ID Diagram Application ● Model the application as it is in the real world and improve the reusability Process
- 13. Concurrent Engineering ● Facilitate communication about design enhancements and process adjustments ● Delegate sections of PROCESS to various stakeholders, not sections of CODE ● Tear down barriers between Maintenance and Engineering departments to get up and running fast ● Several users can work on the same libraries and applications simultaneously from different work stations ● Check-in and check-out features are managed by the system and the user is always informed about the status of the applications
- 15. Object Oriented
- 16. An integrated object offers consistent functionality throughout the system The model is open and extensible so engineers can build their own objects if needed The system takes care of the application lifecycle, managing the changes needed throughout the plant life Ensures consistency across your system and drives operational efficiency Object Oriented
- 17. ●Dedicated Libraries ●Control Devices ● Drives, motor starters, power meters, energy consumption, etc. ●Process control ● Signal conditioning, process loop, sequence logic, motor control, etc. ● Users can modify and/or create their own libraries ● With diagnostic and maintenance information for operators and maintenance staff ●User guides, maintenance procedures, etc. Dedicated Process Libraries
- 18. Built-in Energy Efficiency ● Real-time power consumption ● Dedicated libraries and application templates to help reduce energy waste ● Built-in “idle state” services for equipment that can be triggered based on stoppages or other process statuses ● Combined production and energy data to generate predictive maintenance alerts for equipment to reduce energy use and downtime
- 19. A Dynamic Demo of the Software that Powers the System
- 37. Make the most of your energy
Notes de l'éditeur
- The Application Manager is to the Process engineer as the Topology Manager is to the system engineer. The Application Manager allows the process engineer to design the process application as it is in real-life (or P&ID) using his own model or applying the ISA88 one or any other model he chooses Usually this process description follows the P&ID diagrams but the user is free to apply his own language or organization. Just like for the Hardware Architectures, the user will describe the process application instantiating process objects coming from the Libraries. During the development of the application the engineer is fully independent from the hardware architecture of the topological description and that strongly facilitates the re-usability of pieces of applications seen as a model.
- Common with DCS NOT A SHELL software that links different programming environments….ALL in one. Example: When you want to create a table in a Word document, it doesn’t link to a separate “table” software, it’s all the same.
- Not passing files back and forth through email Doesn’t make sense from a process perspective to have a “HMI” expert or a “Controls” expert…you want a “mixing” expert Not using physical drawing sets or paper documentation at bottom of cabinet as a “go between” between physical devices and program elements.
- Turning to some of the features inside the PlantStruxure Architecture System User Interface. From one single point, the Topological Manager, the engineer (or system architecture expert) has the ability to design and configure the entire system architecture. That includes the devices, field buses, remote IOs, controllers, and the network and supervision architectures. To do so, the Topological Manager provides the needed catalog of hardware objects coming from the libraries. Once designed, we offer the view of the entire architecture from a single point with both trees list and graphical views. Most systems available today only have partial views, basic tree views or different tools to deliver the same level of information.
- Let’s take a look at the PROCESS ENGINEER’s VIEW…Starting from the P&ID of the plant, the process engineers identify the different units, equipments and control modules. A control module is defined in the system as a PlantStruxure PES Object. A PlantStruxure PES Object is composed of different elements like control logic, graphic representation, documentation, manuals, etc.
- Each of the libraries delivered with the system are made up of a set of “objects”, and each object has several “facets”. These facets deliver the functionality to the user during engineering and also during operation. An example of an object would be a pump. The facets of a pump are Genie – the picture on the operator screen that the operator sees to recognize the pump Faceplate – this is the pop-up that provides operational information to the operator Alarms – these are activated if there is something abnormal with the process, typically indicating that the operator needs to take some action Asset management – if the device supports it, the asset management facet allows engineers and maintenance teams to configure and change parameters in the device (through built-in web servers in the device or FTD/DTM technology) Control – the code running inside the controller that gives the device its functionality Link – the link to other objects in the system to aid in navigation Manuals – documentation such as instruction manuals, videos or any other kind of information that should be associated with the object Trend – short-term or long term historical data about the pump In addition, the object model is open and extensible allowing the engineer to modify or build his/her own set of objects. This openness is a differentiation from many DCS offers on the market. Even though their systems support objects, quite often those objects are closed and cannot be edited, making it difficult for engineers to customize to their applications. As the objects can be modified by the user at any time to adapt them to the process, it’s a key point that the system manages properly the propagation of these changes in the existing applications using instances of these objects. This allows the engineer to propagate selectively to chosen instances the changes performed in a template. In order to help the operator along the operation and maintenance phase, the objects will manage all the available diagnostics information to reduce the downtime of the installation, helping the user to make the right decision faster. While instantiating an object, the user selects a device object template and the field bus that he/she wants to use. That will allow the system to build automatically all the communication between the device and the controller which manages it. Everything is done at the same time and the consistency is managed and maintained by the system. During development it saves a lot of time and risk.
- One of the key differentiators of the system is the fact that we can help customers to manage their production and energy within a single environment and reduce energy waste at the source. PlantStruxure PES offers three key features that help to reduce energy and plant downtime The first feature is dedicated libraries and application templates. Specific libraries and application templates for energy devices such as power meters, power protection relays, and energy dashboards are available for use within the system The second feature is the « idle-state » services built into specific objects in order to put them into a predefined state based on another process input or time schedule. The last key feature is the ability to use production and energy data to initiate a predicitve maintenance alert for pieces of equipment. For example, a compressor is designed to produce air at a predefined pressure. As the compressor ages and it starts to wear, the amount of energy consumed to produce the same amount of air under pressure increases because the compressor is no longer as efficient as before. Thanks to PlantStruxure PES, the system can generate an alert for the operator or maintenance personnel so that maintenance can be performed on the compressor before it fails, thereby saving potentially many hours in downtime for the plant. This is only possible by combining energy data and production data.
- In RUN TIME, Operators can Operate the Plant taking the benefits of the object oriented approach, and if needed powerful diagnostics can be enabled to avoid downtime, …. Documentation, Manuals, web access are inherit to the object, and if needed PES allows you to navigate from the supervision system to the control logic in the controller to quickly identify the root cause of any failure.
- In RUN TIME, Operators can Operate the Plant taking the benefits of the object oriented approach, and if needed powerful diagnostics can be enabled to avoid downtime, …. Documentation, Manuals, web access are inherit to the object, and if needed PES allows you to navigate from the supervision system to the control logic in the controller to quickly identify the root cause of any failure.
- In RUN TIME, Operators can Operate the Plant taking the benefits of the object oriented approach, and if needed powerful diagnostics can be enabled to avoid downtime, …. Documentation, Manuals, web access are inherit to the object, and if needed PlantStruxure PES allows you to navigate from the supervision system to the control logic in the controller to quickly identify the root cause of any failure.