Building your system architecture - Schneider Electric

SolutionsfortheMiningIndustry

Beyond our products, our solutions integrate theFromelectricaldistributiontoMEShighest performance software tools on the market.Developed by our R&D teams, they are designedto complement one another, simplify the workof your designers and improve your productivityat all levels of your mining process.PowerElectricalDistributionEnergyManagementIMCCCriticalPowerDevicesAutomationSupervisionObjectsDatabase VariablesNetworksProcessControlLibraryKnowledge Based SystemsServicesMESSchneider Electric Industries SASHead Offi ce89, bd Franklin Roosevelt92506 Rueil-Malmaison CedexFRANCEwww.schneider-electric.comDue to evolution of standards and equipment, characteristics indicated in texts and imagesin this document are binding only after confi rmation by our departments.Design: pemacoPrint:DIACED1308020ENART.835800Package ref. DIACED1308024EN - ART.83581207/2008

iningextractionand beneficiationprocesses Form

LIMSQuality Control RoomPIMSMES3Asset managementControl RoomOperator working sta561HistorianServerSCADAServers17820VoIPPhone9Visual ImageAnalyser2210Instrumentation11Level detectorLube systemPlugged chuteOtherInstrumentationOverflow detectorViscosity meterFlow meterOtherInstrumentationLevel detectorAbsolute encodersCollision detectorsOtherInstrumentation21Safetye-stopSafety zerospeedOtherInstrumentationAmine dosagevalveFlow meterLevel detectorOtherInstrumentationBed leveldetectorsTurbidity sensorCalorimeterOtherWeight scalesOther1516141213Crusher Classification Reclaimer & Stacker Conveyor FlotationThickener

tionEngineering station19Remote OWS42Internet1Vijeo Citect andVijeo Historian servers2Vijeo Citect andVijeo Historian clientsMaintenance3Asset management tool4Remote Web SCADA client195Expert tools6Ampla MES7Dual Ethernet fi beroptical ringTo OperatorWorking Station89ConneXium managed switchesSCADA client10Modicon Quantum PLC11Instrumentation Profi bus PAGSM/GPRS, PSTN,Radio, LLMaintenanceOperator12Altivar 1000 MV variablespeed-drive13iMCC232518141516TeSys U and TeSys Tmotor controlAltivar 61/71 variablespeed driveSepam protection relayInstrumentationParticule sizeanalyserDensity analyserFlow rate detectorOtherInstrumentationFlow meterPressureFlowswitchindicatorOther26Instrumentation24Water leveldetectorPressureFlow meterOther17Electrical Distribution17181920212223Power Meter PM7/8/…Circuit Monitor 3000/4000Unity Pro & Unity ApplicationGenerator softwareLong distance Ethernet radioXPS Preventa SafetyMagelis iPC HMIW@DE315i RTU24Modicon M340 PLC2825Magelis XBT GT HMI2729262728ETG1000 FactoryCastgatewayAltistart 48 motor starterAdvantys distributed I/OMillTailings PumpingWater Reclaimation29Motor Starter TeSys Uon Advantys STB EPI2145

Vijeo>Vijeo>M>Mining>ModiconAn>With>In>Thanks+>SafetyM Fe system architecture supports the moving of huge quantities of raw materials andextracting as much valuable ore as possible ensuring you will get the most from your mine.This is done in the most cost-effective manner while preserving safety of your personneland respect of the environment.Citect improves the automation processInformationmanagementthrough continuous monitoring that identifi esbottlenecks, increases equipment utilization andquality production and reduces maintenance costs.Together, improvements in these areas lead tolower cut-off grades and in effect, expansion of orereserves.Quantum perfectly suits complexProcessControlprocesses. The power of the Modicon Quantumprocessor results in optimum cycle times,simultaneous and fl exible communication capabilities,diagnostics, memory fl exibility and data storage. Dueto the harsh, dusty and corrosive environment, remoteI/O drops are normally used in an enclosed controlroom. RIO architectures on a coaxial cabling schemeprovide long distance capability of up to 4,572 km(15,000 ft) with coaxial cable or longer, with optionalfi ber optic cable.Historian is a powerful reporting analysistool. It bridges mining process and corporatenetworks. On-demand or scheduled reportingto management or other entities can be easilystructured and provided. Utilizing a standarddatabase such as an MS SQL server allows easytransition of data between the process system andthe business system. The data is stored securely.Vijeo Historian leverages the security of the SQLserver. The data can be visualized within the weband Excel clients.Fe system architecture integrates Ampla MES(Manufacturing Execution Systems) that allows youto streamline your production process - increasethroughput, eliminate downtime, reduce wastage,improve quality levels, track resource genealogyand more. By connecting, transforming andpresenting information in real-time, throughoutthe enterprise, Ampla allows you to compare yourproductivity against best practices worldwide andmake intelligent decisions based on accurateinformation. Ampla contains a suite of modules(Ampla Metrics, Ampla Production, Ampla Downtime…)allowing users to tailor the system to their needs.architectures can be very complex andthere is no single solution that will fi t all. A miningfacility can have 15 to 100 PLC controllers, 5000 to300,000 I/Os (digital and analog), 200 to 2000 motorstarters, 500 + instruments and approximately32 equipment areas. Therefore, the emphasis onM Fe architecture is simplicity, fl exibility and adaptability.Ethernet ring assures reliable and highperformance communication between controllers andthe SCADA system. Ethernet ConneXium switchesprovide a “self-healing” ring topology for maximumavailability. The ConneXview Ethernet diagnostic tool,designed for both the Ethernet experts and novice,notifi es the user of a potential problem or alarmto minimize downtime.Unity Application Generator and its objectlibrary, a mining project can automatically confi gurethe networks in multi PLC systems which increaseeffi ciency, improve software quality, speed upcommissioning while simultaneously reducing projectrisk. Integrated change tracking and automaticdocumentation generation reduce engineering effortand enable system validation of your plant.order to improve process performance andmaximize capacity, the control and monitoring ofprocess instrumentation such as particle sizing,plugged chute sensors, fl ow detectors, or levelmeters is mandatory. A specialized ModiconQuantum Profi bus DP module, which includesa Profi bus interface, supports Profi bus PA slaveson the network through DP/PA couplers or links.Up to 125 slave devices with repeaters and extendeddiagnostic data can be managed per module.to FDT/DTM technology, the assetmanagement tool can seamlessly access fi eld devicesfrom the information level. It integrates an Ethernetport that links the Profi bus network directly to theEthernet network with transparency.is always a top priority and both personneland machinery need protection. Preventa XPS offerssafety modules such as Emergency stop, switches,zero speed, time delay… that is ideal for isolatedlocations such as the conveyor.

TheMotor>AnOther + ThePower>Output +Due M>BetterAbility CircuitCircuit + can require a signifi cant number of motors,MotorControlpumps, fans and valves to control. Up to 2,000motors are located in the different process steps.A high level of motor protection and measurementis required to improve system performance and toreduce energy consumption.The MotorSys iMCC and Model 6 solutioncombines the most dependable low voltageswitchboards (IEC or NEMA standard), the mostwidely used motor feeders in the world, the latestgeneration of protection and motor control systems.MotorSys iMCC with Okken or Blokset highavailabilityswitchboard for mining application allowsyou to optimize wiring, maintenance and fl exibilityof your system.control Tesys T, Tesys U, and variablespeed drives such as Altivar can be used in Okkenand Blokset switchboards.Ethernet connection allows you to achievea high level of diagnostic and enhanced performance.networks, such as Profi bus DP, can be usedto comply with local standards.to its powerful materials transformationEnergyEfficiencyprocess, mining requires large amounts of energy(electricity, fuel, etc). This implies environmentalconsequences in terms of toxic emissions and otheratmospheric contaminants.Fe system architecture integrates a powermetering solution to monitor energy consumption andallow energy saving. The PowerLogic Power MeterSeries 700 and 800 offers all the measurementcapabilities required for monitoring an electricalinstallation in your mine. By employing sophisticatedpower monitoring equipment to analyze historical andreal-time data, plant managers can reduce the costof electricity and improve quality and reliability.understanding of electrical system loadingand demand. Improved understanding of entireelectrical system.troubleshoot system problems such asfaults or harmonics.Monitors (CM3000/ CM4000) are typicallyused to monitor the power system parameters onmedium voltage switchgear, motor control centers,480 V substations, and switchboards.Monitors enhance your ability to understandyour mining system completely and troubleshootwhen needed.>MiningAltivar 1000 is a range of mediumvoltage PWM IGBT speed controllers that aredesigned for induction motors used on miningequipment (crushers, stackers, reclaimers...)from 0.5 to 10 MW.voltage: 3,300 V.The basic offer includes the speed controller,transformer and, if required, the motor. Becausethis solution is based on a robust and compacttechnology, you would optimize your investment andimprove the productivity of your mining operation,while reducing your energy costs. Furthermore,Altivar 1000 is designed to not affect the environmentadversely (supply system, processes, etc).

Vijeo>By>Citect web clients allow operators or plantmanagers outside the control room to access controlsystem data in real-time.stackerandreclaimer. Remotelycontrolyourplacing the TeSys T within a ring, usingConneXium’s HIPPER-Ring, communication isautomatically re-routed in less than 0.5 seconds ifthere is a single failure. If the TeSys T should fail,simple remove the faulty device, set the new TeSysT rotary address to the same address as the faultywithdualEthernetTCP/IPports providesahighlevelofreliability andfaultydevice(FDR)capabilities. TeSysTmotormanagementsystemdevice and reconnect to the network.Schneider Electric Industries SASHead Offi ce89, bd Franklin Roosevelt92506 Rueil-Malmaison CedexFRANCEwww.schneider-electric.comDue to evolution of standards and equipment, characteristics indicated in texts and imagesin this document are binding only after confi rmation by our departments..Design: pemacoPhotos: Creatas/JupiterimagesPrint:DIACED1308021ENART.83580207/2008

iningextractionand beneficiationprocesses Form

LIMSQuality Control RoomPIMSMESProcess Optimisation3Asset managementControl RoomOperato5 67HistorianServers1SCADAServers18209Visual ImageAnalyser1021Instrumentation11Level detectorLube systemPlugged chuteOtherInstrumentationLevel detectorAbsolute encoderCollision detectorOtherInstrumentationParticule sizeanalyserDensity analyserFlow rate detectorOtherInstrumentationAmine dosagevalveFlow meterLevel detectorOtherInstrumentationBed leveldetectorsTurbidity sensorsCalorimeterOtherInstrumentationFlow rateOnline sampleanalyserTemperatureOther1615141213Crusher Reclaimer & Stacker Mill Flotation Thickener Hydrometallurgy

working station Engineering station 19Remote OWS42Internet191Vijeo Citect and Vijeo Historian servers2Vijeo Citect and Vijeo Historian clients3Asset management toolTo OperatorWorking Station45Remote Web SCADA clientExpert tools6Ampla MES7Dual Ethernet fi ber optical ringGSM/GPRS, PSTN,Radio, LLMaintenanceOperator89ConneXium managed switchesSCADA client10Modicon Quantum PLC1811Instrumentation Profi bus PA231213Altivar 1000 MV variable speed-driveiMCC22241415TeSys U and TeSys T motor controlAltivar 61/71 variable speed drive16Sepam protection relayInstrumentationFlow meterPressureFlowswitchindicatorOther25InstrumentationWater leveldetectorPressureFlow meterOtherElectrical Distribution17171819202122Power Meter PM7/8/…Circuit Monitor 3000/4000Unity Pro & Unity ApplicationGenerator softwareLong distance Ethernet radioMagelis iPC HMIW@DE315i RTU272324Magelis XBT GT HMIModicon M340 PLC2628252627ETG1000 FactoryCast gatewayAltistart 48 motor starterAdvantys distributed I/OTailings PumpingWater Reclaimation28Motor Starter TeSys Uon Advantys STB EPI2145

VijeoVijeo Vijeo>>MDue>Modicon>FlexibilityAA+ For >AnEthernet> M CU/AU system architecture supports the moving of huge quantities of raw materials andextracting as much valuable ore as possible ensuring you will get the most from your mine.This is done in the most cost-effective manner while preserving safety of your personneland respect of the environment.Citect provides redundancy capability,Informationmanagementalarm management and accurate reporting to ensurecontinuous and smooth plant operations. VijeoCitect’s redundancy will tolerate failure anywherein your system with no loss of functionality. Theimpressive redundancy features of Vijeo Citect canbe used with redundancy of network, fi le servers anddifferent tasks (I/O, trends, alarms, reports, display).Historian, a powerful reporting analysis toolthat supports redundant control system links. In theevent of failure, the historian will request data fromother links or servers.to the complexity of building a new mineProcessControlinfrastructure, the mining complexity may start offsimple but become complex over time as miningoperations expand. Because Mining architecturescan become very complex, emphasis is placed onsimplicity, fl exibility and adaptability.Quantum is perfectly suited for themining industry. Modicon Quantum provides an easyto install, to operate and to maintain solution. Forapplications that have harsh environments, remotelymounted I/O drops in a protected environment suchas the MCC room, provides a powerful Remote I/O(RIO) solution. RIO architectures on a coaxial cablingscheme provide long a distance capability of up to4,572 km (15,000 ft) with coaxial cable or longer,with optional fi ber optic cable.Citect Reports helps your plant and ITpersonnel to optimize data usage by providinga powerful, enterprise-wide reporting tool thatcollects, stores and delivers meaningful reportingdata from multiple, disparate systems. A range ofpre-confi gured alarm management reports basedon the EEMUA 191 Alarm Management guidelinesare included and serve as the de-facto standardfor the industry. By utilizing these reports, alarmmanagement, alarm rationalization and prioritizationimprove your plant’s effi ciency. It also enables plantmonitoring and control to become a continuousprocess instead of a milestone.Cu/Ausystem architecture integrates Ampla MES(Manufacturing Execution Systems) that allows youto streamline your production process - increasethroughput, eliminate downtime, reduce wastage,improve quality levels, track resource genealogy andmore. By connecting, transforming and presentinginformation in real-time, throughout the enterprise,Ampla allows you to compare your productivity withthe best practices worldwide and make intelligentdecisions based on accurate information. Amplacontains a suite of modules (Ampla Metrics, AmplaProduction, Ampla Downtime…) that allows users totailor the system to their needs.of RIO architectures to meet your needs:redundant cable RIO topology that may beneeded in area of the plant such as the grinding mill.fi ber optic RIO connection to different parts ofthe plant.critical processes (for example the watercaption), the Hot Standby Modicon Quantumprocessor is designed to assure high controlsystem availability. The Hot Standby Quantumsystem offers remarkable computing and switchoverperformance that perfectly meets the requirements ofa complex mining operation.Ethernet ring assures reliable and highperformance communication between controllers andthe SCADA system.ConneXium switches provide a“self-healing” ring topology for maximum availability.

The>TeSys+TeSysTeSysTeSys>+ AltivarAltivar>The+>PowerOutputThe> + mine can have 50 over 2000 motors, pumpsMotorcontrolmanagementand valves to operate and control. The M Cu/Ausystemarchitecture provides an integrated solution withdifferent types of motor controls to offer a basic andeffective level of motor protection and measurement.TeSys U starter-controller is a direct motorstarterwith a capacity of up to 32 A/15 KW,that performs the following functions: protectsand controls single phase or 3-phase motors,disconnects power, protects against over currentand short-circuit, protects against thermal overload,performs power switching, application control,protection alarms, application monitoring: duration ofuse, number of faults, motor current values, etc.U is well adapted to control the motors ofconveyors, bucket elevators and equipments of thedifferent process steps of your plant.T motor management system covers alladvanced motor monitoring and protection needsin mining installations where productivity and a highlevel of availability is essential. It offers a wide rangeof current rating, a high level of protection and anall in one device with all main protection and controlfunctions. Complementary protection functions areavailable with an expansion module.T is offers the assurance to have completemotor protection and measurement even in the mostcritical process step such as fl otation process.T motor management system with dualEthernet TCP/IP ports provides a high level ofreliability and faulty device (FDR) capabilities.61/71 connected variable speed drivesmeet the most stringent requirement of miningplants, boosting performance and increasingfl exibility of use.71 offers a full range of variable speeddrives (IP20, IP23 and IP54 enclosed) that meetmining plant motors requirements (grinding mill,dust collector…)- 0.37 to 90 kW - 200/240 V- 0.37 to 630 kW - 400/480 V- 4 to 800 kW - 690 VAltivar 1000 is a range of medium voltagePWM IGBT speed controllers designed for inductionmotors used in mining (crushers, grinding mill, ...)from 0.5 to 10 MW.voltage: 3,300 V.basic offer includes the speed controller,transformer and, if required, the motor.Because this solution is based on a robust andcompact technology, you would optimize yourinvestment and improve the productivity of yourmining operation, while reducing your energy costs.Furthermore, Altivar 1000 is designed to not affect theenvironment adversely.>A

The>Dust,>>Thecomplexity of automation architecturesOptimizeprocessdesignandcontrolin a mine requires a high level of diagnostics andConneXview Industrial Ethernet Diagnostic Softwareis the perfect solution. ConneXview lets you monitorand troubleshoot your entire Ethernet network fromyour PC or anywhere you have network access.corrosive products, humidity, and sea aircan all cause signifi cant damage to equipment.enclosed Altivar 71 constant torque offerand the enclosed Altivar 61 variable torqueoffer both provide ingenious solutions.Altivar71andAltivar61 IP23/IP54enclosuresforSchneider Electric Industries SASHead Offi ce89, bd Franklin Roosevelt92506 Rueil-Malmaison CedexFRANCEwww.schneider-electric.comDue to evolution of standards and equipment, characteristics indicated in texts and imagesin this document are binding only after confi rmation by our departments.Design: pemacoPhotos: Digital Vision/Hans-Peter Merten, Fotolia/Steve LovegrovePrint:DIACED1308022ENART.83580407/2008