Mining, Minerals and Metals - Schneider Electric
Mining, Minerals and Metals - Schneider Electric
Mining, Minerals and Metals - Schneider Electric
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<strong>Mining</strong>, <strong>Minerals</strong> <strong>and</strong> <strong>Metals</strong>“MoreMegatons.FewerMegawatts”
Our VisionA world where we can all achieve more whileusing less of our common planetWho We Are?The global specialist in Energy ManagementOur MissionWe help our customers to do the most withtheir Energy2
Being a Global Company…3
Head Office – Midr<strong>and</strong>Warehouse: Bartlett (Is<strong>and</strong>o)Regional Offices: R-Bay, DBN,PE, CPT, BLM, Nelsp, GeorgeJohannesburg Execution CentresProjects & Services (MV ED)LV Equipment Division (LV iMCC)Drives Competency Centre (VSD & Eng Drives)Professional Services (Automation Systems, MES)APC (Critical Power & Cooling)4
●BBBEE Status - Currently on Level 4●CIDB Rating●ISO 9001●PMBOK- 7EP Rating- Certified Quality Management Engineering- Project Management Professionals (PMP)®●AdvantageOne - Project Life Cycle MethodologyBest in Class ProductsSolutionsServices & ProjectsEnergy ManagementIEC&NEMAMV/LV EquipmentConsultationEnergy Efficiency AuditsEngineered VSDsCritical Power & CoolingInstallation AssessmentIndustrial PerformanceIntelligent MCCsProcess Control SystemsRetrofitsEngineeringTurnkey Solutions5
Our Mission●6
…because Energy is your Most Important(transformation) Process VariableRawMaterialEnergyTransformationProcessFinishedProductWasteEnergy ManagementPlatform(power & control)8
Comprehensive & Integrated <strong>Mining</strong> SolutionsProfessional ServicesManufacturing Execution SystemProcess controlMachine controlMotor control<strong>Electric</strong>al distributionPower monitoring & controlSecurityBuilding ManagementCritical powerData Centers ControlSustainability● Energy Efficiency● Waste Reduction● People, health <strong>and</strong> safetySimple IntegrationCompetitiveness● Capex & Opex reduction● Increased availability● Eased innovationInteroperability <strong>and</strong> opennessto third party systemsFlexibility & Safety● Critical points management● Reliability● Seamless Evolution9
Integrated Automation & Power System ArchitectureUPSERP SystemHistorianMineExecutionSystemEnergyEfficiencySystemRedundantSCADASystemServersOperator ClientsEngineeringStationEnergyManagement &Control SystemEthernetPACOn-LineParticleSizeAnalyzerOptimization& APCPACProcessCameraEnergyMonitoring &MeteringDistributed <strong>and</strong>Remote IOMotorControlCentreMVSwitchgearInstruments <strong>and</strong> Devices11
<strong>Mining</strong> Facility & Buildings ManagementComprehensive BuildingManagement, CCTV, Access Control<strong>and</strong> Energy Management Solutions tocompliment the Industrial AutomationSolutions
<strong>Mining</strong> Facility & Buildings Management
Critical Power BackupAvoid any Interruption of Power Supply forProcess Control Equipment, IT Infrastructure<strong>and</strong> Security Systems
UPS, Critical Power & Cooling●High efficiency at low, medium <strong>and</strong> high load levels●From 19” Rack Mount to Tower Mount to CompleteData Centre Solutions●Extended range automatic voltage regulation (AVR)●Pure Sine wave output●Simple Serial or Ethernet Integration into SCADASystems for Maintenance & Diagnostics●Add external battery packs to scaleruntime from minutes to hours
Power Monitoring <strong>and</strong> ProtectionIntelligence in all Medium Voltage <strong>Electric</strong>alDistribution equipment such as Breakers <strong>and</strong>Protection Relays provide effectiveMonitoring <strong>and</strong> Control of the <strong>Electric</strong>alNetwork
<strong>Electric</strong>al Distribution Systems
MV leader with best-in-class SolutionsSCADA DistributionManagement SystemProtection relaysMV Primary cubiclesPrefabricated MV/LVcubicles forsecondary substationMV/LV transformersCapacitorsMV cubiclesElectro-IntensiveUtilitiesHV/MV prefabricatedfactory-assembled <strong>and</strong>engineered substationPrimary switchgearMV ring main unitsCircuit BreakersMV cubiclesDistribution automation:Feeder automationRemote controlDigital Protection relaysMV ring main unit
Power MeteringBest in Class <strong>and</strong> World Leaders inPower Metering to provide the mosttrusted <strong>and</strong> comprehensive solution tomake the Power information availableto facilitate Energy savings.
Energy ManagementEnterprise Energy Management toolsto quantify the cost of energy <strong>and</strong>relate it to your everyday business
Energy Management SystemsEnterprise EnergyManagerION EnterprisePower MetersPowerView
Intelligent Motor Control70% process downtime reduction90% fewer motor burn-outs
Intelligent Power & Motor Control CenterAdvancedProcessControlMotor ControlProtectionEnergyManagement
Low Voltage Equipment Division●Market Leader in switchgear systems & Solutions●Products carry the SABS mark●ISO 9001:2000 quality management listing●Merseta-accredited training provider●Comprehensive manufacturing capability & facilities●Huge install base (>25,000 sections)Switched onto excellence
Engineered Variable Speed DrivesDrive Solutions that bring directimpact in motor <strong>and</strong> equipmentefficiency <strong>and</strong> power savings
Engineered Drive Solutions• Medium Voltage Drives up to 10MW• 2.4/3.3 / 4.16 / 6.6 kV• Low Voltage Drives up to 2.4MW• 400/690V drives with solution approach• Package Solutions:• Transformer, Drive <strong>and</strong> Motor• Cooling: Air <strong>and</strong> Water• Regenerative Braking Solutions• Integrated harmonic mitigation(12/24/36 pulses, AFE, Filters)• Compatibility with new/existing motors <strong>and</strong> Fieldbus• Induction <strong>and</strong> Synchronous motor control• High level of reliability:• Redundancy in cooling pumps <strong>and</strong> fans,• Reliable components
Other Drive systems●Mine Winders●DC <strong>and</strong> AC Frequency Drives●AC Soft Starters●Medium Voltage Starters●Static Excitors●Multi-Pump Control●Anti-Sway Crane Control●Rotor Control Solutions●Industrial Power Electronics●High-Speed DC Breakers●Custom Electronic Controls●Electronic Lilly Controllers●ABS Brake Controllers
Drives Competency Centre:2x315kW VSD Winders●Shaft Sinkers Teesta (India) project●2x315kW Containerized Mine Winders●R6.2M●VSD, PLC, HMI, Automation Software,Sensors, TeSys U●Fully integrated <strong>and</strong> Engineered Solution●Sold another 2 units as “st<strong>and</strong>ard” solution<strong>Schneider</strong> <strong>Electric</strong> - Division - Name – Date28
Process Automation SystemCombined automation <strong>and</strong> energyefficiency in a common architecture
Process Automation SystemPlantStruxureArchitecture & NetworksEngineering StationOperating & MonitoringControllersDistributed IO <strong>and</strong> DevicesHigh AvailabilitySafety Instrumented SystemRemote Terminal UnitsHistorianManufacturing Execution SysBusiness System ConnectivityKnow more …
Our Control SystemDiscrete control requirementsDevice IntegrationHigh speed logicMultitasking controller OSMotion & machine controlSt<strong>and</strong>-alone operationScaleable architectureDistributed IOProcess control requirementsHot St<strong>and</strong>byPeer to peer commsDistributed functionalityProcess librariesRegulatory controlAdvanced process controlRemote IOOnline changesRuggardisedMore …SafetyExtensive communicationFaulty Device ReplacementHot-swap
Configure the entire systemConfigure theSCADAArchitectureCADIntegrationConfigure theNetworkarchitectureConfigure thedevicesConfiguretheRemote I/OsConfigure thePLCsTo configure thePLCPLCcommunication
Advanced Process ControlSaving potentialImplement Advanced Process controlto deliver 3% to 10% lower powerconsumption (kWh / ton) - grindingcircuitOut ofspecsPID ControlAdvanced Process Control
Advanced Process Control Solution●Embedded advanced process control functionalities● Model Predictive Control (MPC)● Fuzzy Control●Dedicated object libraries●Configured using our st<strong>and</strong>ard engineering tools●No third-party software required
Energy Control FDS●Interlocking of non-essential Energy Consumers during peak periods●Load Shedding – OFF / Reduced speed for non-essential devices●Priority Scheduling <strong>and</strong> Sequencing● Time-of-Use-Tariff Scheduling● Multi-Pump Sequencing (Underground Water Movements, Water Makeups,Stockpile Movements, Compressor Start-ups)●Implementation of Intelligent Power <strong>and</strong> Motor Control Devices● Real-Time Power Consumption per Individual Device● Benchmarking – Alarming <strong>and</strong> Predictive MaintenancePower ILLoad SheddingLS Setpoint: 30%
<strong>Mining</strong> Execution SystemOpportunities for processimprovement can only be properly<strong>and</strong> fully evaluated once Data hasbeen transformed into contextualizedInformation to empower effectiveImprovement Initiatives
<strong>Mining</strong> Execution Systems“<strong>Mining</strong> Execution Systems deliverinformation that enables the optimisationof production activities from orderlaunch to finished goods”
Reference:Voorspoed Diamond Mine●De Beers – Voorspoed Mine●Complete Automation System●R12m Project Value●PLC Panels, PLC Equipment <strong>and</strong> Engineering, SCADA System,Industrial Networks, Historian, Ampla MES System,Commissioning, H<strong>and</strong>-over <strong>and</strong> on-going Support●PS St<strong>and</strong>ards – 5 Months Engineering for complete system!Plant Optimized duringHot Commissioningthrough Ampla MES<strong>Schneider</strong> <strong>Electric</strong> - Division - Name – Date38
Production Energy OptimizationEnergy Events can be identified <strong>and</strong>the Process reasons understood toenable future preventative action.
Engineering <strong>and</strong> Project ManagementBest Practice Engineered AutomationSolutions <strong>and</strong> St<strong>and</strong>ard <strong>Mining</strong>Library perfectly suited to the mostdem<strong>and</strong>ing MMM Project
Professional Services………..a Partnership ApproachHow can I more easily turn this into this …?● Functional Specifications● Wiring diagrams● P&ID diagrams● Other….● A fully functional Automation System41
Best Practice Solution Engineering●Large Projects Implementation Experience in Southern Africa●Deep <strong>Electric</strong>al <strong>and</strong> Automation Industry Experience & Underst<strong>and</strong>ing●Proven Project Management & detailed Implementation Methodologies●Industry Leading St<strong>and</strong>ards set for Industrial Applications●Full Project Life Cycle Approach●Global Coverage <strong>and</strong> Growth42
AdvantageOne TM• Life Cycle Approach• Staged approach: Engage to Optimise• Captures Experience• Tools, St<strong>and</strong>ards, Forms, Templates• Industry Best Practices• Includes PMBOK knowledge areas• ISO 9001 certified Quality Management System• Assists with Lean & Six Sigma Improvement initiatives• ISA-95• Benefits• Reduce risk• Sustainable results• Maximise solution acceptance & business returns43
Project Life Cycle StagesDiscoverDefine Goals, Objectives, Benefits & Success MeasuresIdentify Project StakeholdersHigh-Level Project Costing & Implementation ScheduleDiscovery Services StudyDefineOperation Requirements, ISA95 Equipment ModelsTechnical Performance Measures, Maintenance &Support SystemsFunctional Analysis & System SpecificationFunctional RequirementSpecificationDesignRequirements AnalysisArchitecture IntegrationUser InterfacePrototype Demonstration(Thin Slice or Deep Slice)Functional DesignSpecificationDevelopProgramming <strong>and</strong> ConfigurationDetailed EngineeringCustomizationTraining MaterialTest Plan & In-house TestingAudit against SpecificationFactory Acceptance TestingFactory Acceptance TestingCertificateImplementLogistics & Safety,Detailed PlanningEquipment InstallationDetailed Commissioning PlanCold & Hot CommissioningOperator Training &Maintenance TrainingSite Acceptance Test CertificateO&M Training ManualsAs-Built DocumentationOptimiseSupport Contracts, Service Level Agreements,Site Audits, Additional TrainingEngineering Assistance & Continuous Improvement44
Multiple Team ApproachSalesPSConsultingPSEngineeringENGAGEDISCOVERDEFINE DESIGN DEVELOP IMPLEMENT OPTIMIZEAccount ManagerBusiness ConsultantBusiness Consultant – Part TimeBusiness ConsultantTechnical ConsultantEngineering Staff3-24+ months<strong>Schneider</strong> <strong>Electric</strong> - Automation Division –Jan 2009
St<strong>and</strong>ards - Overview●SCADA & PLC St<strong>and</strong>ards●SCADA St<strong>and</strong>ards Project●PLC St<strong>and</strong>ards Project●Generation Software; UAG, Excel <strong>and</strong> Templates●Documentation●SCADA & PLC Functional Design Specifications●Device Control Modules, Equipment Modules & Sequence Functionality●Operator <strong>and</strong> Maintenance Manuals●Installation, Configuration <strong>and</strong> Maintenance Procedures●Testing, FAT, SAT <strong>and</strong> Commission Plans & Reports46
St<strong>and</strong>ards - History●Started development early 2000’s●Used on most Projects <strong>and</strong> continuously evolved●Updated to keep leading edge in Market●Meets <strong>and</strong> exceeds client’s requirements●Use Product Enhancements to accelerate st<strong>and</strong>ards development●Speed up engineering <strong>and</strong> sign off●Maintenance enhancements●Client feedback on enhancements●Simplification of the st<strong>and</strong>ards kernel47
St<strong>and</strong>ards - Benefits●Almost all new Projects use this st<strong>and</strong>ard●Tested multiple times <strong>and</strong> incremental testing only required●One st<strong>and</strong>ard to underst<strong>and</strong> <strong>and</strong> Maintain●Enhancements done on one st<strong>and</strong>ard●Quotation calculations based on st<strong>and</strong>ards – repeatable & scalable●Enables confidence with Fast-track <strong>and</strong> penalty projects●Minimal first principal engineering●St<strong>and</strong>ards proposed at enquiry phase●Engineers can be changed on projects●…….<strong>and</strong> more…48
St<strong>and</strong>ards Vehicle –Unity Application Generator (UAG)• Reduced Cost & Project Schedules• System implementation cost savings.• Reduced risk <strong>and</strong> improved projectschedules.• Improved time to market by allowing theproject to go live <strong>and</strong> give return oninvestment sooner.• Improved Quality• Improved software quality.• Improved maintenance.• Continuous Performance Improvement• St<strong>and</strong>ardized design <strong>and</strong> systematicimprovement.• Reusable customer best practices.[ Save 20% to 35%on project schedules! ]49
St<strong>and</strong>ards – UAG System Overview• Single design environment <strong>and</strong> single database for multiControl System, HMI-Supervision based systems.• Structured Project Design:•Consistent use of st<strong>and</strong>ard Naming Conventions,Programming Style <strong>and</strong> Structure provides for aSavings in the Implementation of a Project• St<strong>and</strong>ardized Object Libraries:•Tested <strong>and</strong> proven•Captured <strong>and</strong> re-used best practices• Automatic Application Generation:•Project control code, graphics <strong>and</strong> database aregenerated automatically• Automatic configuration of networks in multi devicesystems.• Change tracking <strong>and</strong> automated documentation.• Open to Third party tools:•Upstream: Process design•Downstream: Supervision, Archiving, Simulation50
St<strong>and</strong>ards - Simulation●Simulation built into PLC device level●In-house testing <strong>and</strong> FAT signed off with full software in simulation●FAT checked against the control narrative●All devices, interlocks, controls <strong>and</strong> sequences tested <strong>and</strong> signed off●Only Physical IO <strong>and</strong> dynamic process timing not tested at the FAT signoff.51
St<strong>and</strong>ards - Conclusion• Reduced system costs.• Reduced risk, improved software quality, improvedmaintenance.• Improved time to market of customer projects byallowing the project to go live <strong>and</strong> enable return oninvestment sooner.• Systematic improvements <strong>and</strong> reusable customerbest practices.52
Ongoing Lifecycle Service <strong>and</strong> Support• Product support• Spare Parts & Repair• Training• Migration services…my plant should operate for 20 years53
Example System Architectures54
Example System Architectures55
Example System Architectures56
Example System Architectures57
Examples: St<strong>and</strong>ards & Popup Sample59
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Complete Solution Suitefor the MMM IndustryPowermanagementProcessmanagementSecuritymanagementCritical PowermanagementBuildingmanagement High Density Metering Power QualityMitigation LV/MV <strong>Electric</strong>alDistribution protection& control Intelligent power &motor control Engineered VariableSpeed Drives Process Control Advanced ProcessControl Visualization <strong>Mining</strong> ExecutionSystem Production EnergyOptimization Best PracticeEngineering &Project Management Access control Video surveillance Emergency lighting Intrusion detection Fire <strong>and</strong> life safety BuildingManagement UninterruptiblePower Supply Cooling control Rack systems Surveillance White SpaceManagement Building ManagementSystems Lighting Control Outdoor LightingControl HVAC Control Power ManagementPowerPlantSecureInfraSmartReliabilityDowntimeAccidentsData integrityEfficiency61
Solution Provider of ChoiceFor <strong>Mining</strong>, <strong>Minerals</strong> & <strong>Metals</strong>62
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