Transcript Wonderware Presentation Template 2007

Maximising control, visualisation and
information at the Mix plant at Lonmin
Brian Davies
Senior Technician
Roelf Boshoff
SI Engineer
Agenda
Introduction
The Project
Benefits of version 3 graphics
Considerations
Technical Challenges
Introduction to Lonmin
► World’s third largest
Platinum producer
► Operations based in
South Africa
▪ North West
▪ Limpopo
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
Introduction to Mix Concentrator
Mix Concentrator processes
► Milling
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Raw ore fed into ball mill
Diluted with water - Slurry
Cyclones separate fine from coarse
Coarse returned to mill
Introduction to Mix Concentrator
Mix Concentrator processes
► Floatation
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Chemicals used to attract PGM’s to bubbles
Primary roughers extract 80-90%
Secondary roughers collect rest
Contaminants removed in cleaning section
Introduction to Mix Concentrator
Mix Concentrator processes
► Thickener – cone shaped
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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
Mix Plant Network Topology
ArchestrA IDE
Workstation
Production
Switch
AOS 1
INSQL
AOS 2
Control
Switch
Galaxy
Repository
Allen-Bradley
Workstation
MIX PLC 1
MIX PLC 2
MIX PLC 3
MIX PLC 4
MIX PLC 5
Agenda
Introduction
The project
Benefits of version 3 graphics
Considerations
Technical Challenges
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
Agenda
Introduction
The project
Benefits of version 3 graphics
Considerations
Technical Challenges
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
Benefits of version 3 Graphics
Superior Graphics
► Enhanced Graphics
► Esthetically Pleasing
► Realistic Graphics
► Air of Professiolism
Benefits of version 3 Graphics
► Enhanced Graphics
Transparency
Embossed
Symbols
Patterns
Benefits of version 3 Graphics
► Esthetically Pleasing
Shaded Tanks
Lighting
Effects
3D Symbols
Benefits of version 3 Graphics
► Realistic Graphics
Oil Filter
Mill displaying
gears
Solenoid Valve
Animated Fan
Benefits of version 3 Graphics
► Air of Professiolism
HMI Time
PLC Time
Control Logix
PLC
Allen Bradley
DeviceNet
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
Benefits of version 3 Graphics
► Add symbols to template
Icon Graphics
Graphic
Description
Inherited from
Master template
Popup
Graphics
Referenced as
me.PopUp
Benefits of version 3 Graphics
► Populate graphics with attributes
Icon Graphic
Template
Attributes
Benefits of version 3 Graphics
► Link popups to icons
Icon graphic
Activate as
Icon
Show popup
on click
Example
Popup
Reference
Popup Graphic
Benefits of version 3 Graphics
Inserting graphics into SCADA is easy
Embed ArchestrA
Graphic
Symbols embedded
in instance
ArchestrA
instance
Benefits of version 3 Graphics
Inserting graphics into SCADA is easy
Symbol embedded
in SCADA
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
Benefits of version 3 Graphics
► Graphic used in another Graphic
Graphic from
graphic toolbox
Original graphic
Another Graphic
Embedded
graphic
Benefits of version 3 Graphics
► Graphic used in the SCADA
(Where graphic is not an icon)
Graphic from
graphic toolbox
Tag entered in
Scada
Benefits of version 3 Graphics
► Graphic used in a template
(Graphic becomes an icon)
Icon used in
SCADA
Symbol name
ArchestrA template
Graphic from
graphic toolbox
Tag already
assigned
Benefits of version 3 Graphics
Added benefit of connection status indication
* Status icon indicates status of the connection to the IO server
Status added to
Icon
Status indication
definitions
Add status
Indication
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
Agenda
Introduction
The project
Benefits of version 3 graphics
Considerations
Technical Challenges
Consideration
► Do not use minimum hardware
specifications for GR
▪ Might cause instability,
▪ Performance issues,
► Network stability
▪ Communication failure
Agenda
Introduction
Objective
Benefits
Considerations
Technical Challenges
Technical Challenges
Flushing Sequence Popup
► To clean a pump that carries slurry before stopping
and starting
► Typical arrangement:
Suction Valve
Flush Valve
Delivery Valve
* Many different
configurations exist
Drain Valve
Slurry Pump
GSW Valve
GSW Analog
Technical Challenges
Flushing Sequence Popup
All the slurry pumps need flushing valves
Not Enough space to display flush valves – Need a popup
Technical Challenges
Flushing Sequence Popup
Flush Button
Opens
Flush Button Indicating
problem in flush sequence
Flush popup template graphic
 7 valve positions
 3 types of pumps
 Analog only constant
 15120 possible
configurations
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
Technical Challenge
Flushing Sequence Popup
► End result
Completely
dynamic popup
Technical Challenges
PLC Layout
WHY?
Indicate module status
Show Inter-PLC communication
Fault Finding
Grapical devicenet represenation
Technical Challenge
PLC Layout
► A standard naming convention makes Archestra
templates possible
► Naming convention
▪ Rack
▪ Slot
▪ Slot in a rack:
example:
R01
S04
R01S04
► Templates created to assign the IO automatically
using the naming convention and containment
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
Technical Challenge
PLC Layout
► The NEW
method
OLD method
Tags Needed for a single
Devicenet Scanner
Tags NeededTags
for: Needed for Slot
Status of a single Rack
• One PLC
• Six Racks
• Two Devicenet Scanners
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
Technical Challenges
BUT
Effective alarm annunciation and
navigation
With the new and improved system
▪ Alarms can be acknowledged from the popup
▪ Type of alarm and priority also indicated
Icon indicating
alarm (Red)
Alarm latch in
PLC indication
Separate button
for reset and
acknowledgement
Alarm acknowledgement
button
Alarm Priority
Technical Challenge
Effective alarm annunciation and
navigation
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HOW was it done?
▪ Create Alarming template
▪ Add attributes to all templates which can alarm
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WindowName
AlarmingEnabled
AlarmType
Use Intouch alarm viewer controls to capture alarms
Use owning object scripts to populate graphics
Link windows to alarms
Thank you for attending
Wonderware User group
Conference 2009
Any Questions?