Transcript Wonderware Presentation Template 2007

Khumani Mining Application
Johann Pienaar
Director, Iritron (Pty) Ltd
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
ASSMANG
► ASSMANG shareholders – ASSORE and
ARM
► Iron Ore, Manganese and Chrome
► ASSMANG sites – Beeshoek, Khumani,
Blackrock, Cato Ridge, Dwarsrivier,
Machadadorp
► ASSMANG standardised on Wonderware
Software in 2000
What is ASSMANG Khumani?
On-Grade W&S
Sample
Tower
Thickener
HPGR
Main
Plant
Paste
Thickener
Jig
Overland
Plant
Conveyor
Mine Area
Primary&Secondary
CrushingOff-Grade W&S
ROM Stockpiles
Architecture
KH-SUITEVOYAGER:
Information Server
SCADA Network A
Networks and Protocols
• Separate IT, SCADA
and PLC networks
• GB single-mode fibre
backbones
• UPS and Generator
backup
• Redundancy
Load-Out
HIPER-Ring
Bruce
HIPER-Ring
Plant HIPERRing
Galaxy: Size Does Matter!
► Khumani Phase 1 (September 2008):
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165 Templates
6,746 Object Instances
48,358 IO
33,636 Historised Tags
► Khumani Phase 2 (2011):
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200 Templates
13,000 Object Instances
90,000 IO
65,000 Historised Tags
IO Servers
► IO Servers:
▪ TopServer for ContolLogix PLCs
▪ DASMBTCP for Online Analysers
► Two sets of Redundant Application
Servers:
▪ Dual CPUs
▪ 2.0 GHz Core 2 Duo
▪ 2GB of RAM
▪ CPU Utilisation:
• AOS1 – Max 24%
• AOS2 – Max 15%
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
System Platform 3.0 Approach
► Naming Conventions
► Modelling and Standards
► Deployment Considerations
► Archestra Graphics
► Automatic Tag Linking
► Instantiating Objects
► Addressing Software Problems
Naming Conventions
► Do Your Engineering Upfront:
▪ Naming Specification
▪ Functional Specification
▪ Detail Design Document
▪ Thin-slice Archestra templates
► P&ID derived naming convention was used
for all object instances:
<site>_<area>_<equip>_<instr>_<signal>
Example: 90_DS50_PU15_FIT01_FI
► Define Template, Attribute, Script and
Graphics naming conventions
Modelling and Standards
► Wonderware
Best Practices
Enterprise
Site
Guideline
► Wonderware System Platform Sub-Area
Checklist
Area
Process Cell
► S95 Standards
Deployment
► “Fine Tuning and Optimisation
of WW System platform”
► Utilise Archestra’s multithreading capabilities on multiCPU servers:
▪ Multiple application engines
▪ Prime number scan intervals for
scan groups
Graphics Approach
► Graphic building blocks were created in
the Graphics Toolbox
► The building blocks were grouped in
Toolsets
► Graphic building blocks were used to create
Object Graphics
► SCADA mimics were created as Local
Graphics in the Area instances
► No graphics were created in Intouch - Each
Intouch page contains a single Archestra
symbol
Graphics Toolbox
► Create all Graphics Symbol building
blocks in the Graphics Toolbox
► Graphic Symbols grouped in Graphic
Toolsets
► Adhered to best practises:
▪ Used only LOCAL Custom Properties
▪ Made internal properties private
▪ Be aware of limited error checking
Graphics Toolbox
Graphic
Toolsets
Graphic
Building
Block
Use Custom
Properties
Object Graphics
Template
Graphics
Object Graphics
Graphic
Building Blocks
Link Object
Attributes
Mimic Graphics
Area Model
Area Instance
SCADA Mimics
Automatic Tag Linking
► Automatic Tag Linking is one of the most
powerful features of Archestra:
▪ Standardised on tag based A-B ControlLogix
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PLCs
Implemented standard blocks in PLC
Rigidly enforced our chosen tag naming
convention
Linked to PLC tags via scripting
Automatic Tag Linking
Automatic Tag Linking
Instantiating Objects
► The fastest method of
creating multiple instances
- use the CSV Export and
Import Object functionality
► Create, then Export an
example instance,
copy/paste the new
instances and Import
► Only keep the necessary
columns
► Use Excel 2007 or later
Zapping Bugs
► We were one of the first companies to start
a System Platform 3.0 project:
▪ ASSMANG Cato Ridge – Started
▪
development on Beta version (July 2007)
ASSMANG Khumani - Started development
on Gold version (Aug 2007)
► Identified NUMEROUS bugs
► Progressed through Patch 1, Patch 2,
Patch 3, SP1, numerous Hot-fixes and
finally SP2!
Bugs
More Bugs
▪
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Copy Paste chaos!
Archestra Graphics: >10min to open!
Managed Intouch Application: >1hr to open!
Duplicate ID’s
Denial!
► During the first 4-months of the project:
▪ We assumed that the issues were being addressed
▪ We did not realize that we were the first to
experience the problems
▪ We blamed most of it on finger trouble and network
problems
▪ We became very creative at finding workarounds
▪ We reported nothing!
Zapping the Bugs!
► From Feb 2008 to Sept 2008:
▪ We started logging ALL issues - we logged more than
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39 issues
The severity of the issues ranged from terminal to minor
irritation
More than 25 Hot fixes, Patches, Service Packs and
Utilities have since been issued by Wonderware to
address these problems
SP1 – We were the 1st and only to install SP1
Support staff from Wonderware EMEA and
Wonderware SA flew out to site on numerous occasions
to investigate the issues
We arranged weekly WebEx teleconferences with
Wonderware EMEA and Wonderware USA
Reporting Procedure
► Reporting chain: SI/Client -> Wonderware SA ->
Wonderware EMEA -> Wonderware USA
► Phone Wonderware support (0861 WONDER) to
determine if this is a known issue
► Send supporting e-mails to [email protected]
and not to individuals
► To fast-track the problem, one has to provide
Wonderware with a RECIPE to replicate the problem
Reporting Procedure
► Recipe:
▪ An in-depth description of the problem
▪ Software versions - Wonderware and Microsoft
▪ Wonderware SMC log-files (.aaLGX) from the View
Node, Galaxy and AOS
▪ Microsoft log-files (.evt) from the Microsoft Event
Viewer – Application, Security an System
▪ Screen-captures (.jpg) illustrating the problem
▪ Galaxy Backup (.cab) or Object Export (.aaPKG)
► Wonderware SA can only escalate the problem to
Wonderware EMEA once they have also been able to
replicate the problem
Reporting Procedure
► KEEP YOUR COOL – We are all in the same boat!
► Before a Hot-fix can be issued to an SI or End-User,
a signed Hot-fix agreement has to be signed
The End Result
► After SP2:
▪ Archestra Graphics: <10sec to open
▪ Managed Intouch Application: <30sec to open
▪ All mayor bugs have been zapped!
▪ The only outstanding issues are nice-to-haves, all
of which I still want!
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Benefits
► Initial development time took longer
than expected due to:
▪ The bugs in the software
▪ The P&ID’s were never frozen
▪ The PLC developers made drastic changes
▪
in their code until very late in the project
Inexperience
Benefits
► However, for phase 2 of the project,
the picture is completely different:
▪ Development time will be drastically
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▪
reduced
FAT Testing and Commission time will be
minimal
No scalability constraints
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Considerations
► The Galaxy Repository is a critical
component. Have an off-line system
available for tests and as backup
► Communicate with Wonderware – bugs
don’t fix themselves!
► TRAINING, TRAINING, TRAINING! Higher
skills level required for Archestra than for
Intouch
► Do your Engineering upfront, BEFORE you
begin with your Archestra development
Considerations
► Manage Archestra biggest
strength/weakness – it’s flexibility
► Draw up a System Checklist for setting
up all computers in the system
► MAKE REGULAR OFF-SITE
BACKUPS
► Be aware of the risks when developing
in a new version of any software
► Make use of VPN Dial-In and Microsoft
Remote Desktop
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Summary
► Communication and Teamwork are
critical
► All software bugs can be overcome!
► We have a happy client
► The Archestra system works brilliantly
► We are looking forward to phase-2 of
the project!
Questions
Questions?