System Platform The Base For Enabling Intelligent Operations At A Gold Mine
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System Platform The Base For Enabling Intelligent Operations At A Gold Mine André Vuilleumier Managing Director
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System Platform The Base For Enabling Intelligent Operations At A Gold Mine. André Vuilleumier Managing Director. Introduction. Project Solution. Agenda. Benefits. Considerations. Summary. Who, What, Where. - PowerPoint PPT Presentation
Transcript of System Platform The Base For Enabling Intelligent Operations At A Gold Mine
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System Platform The Base For Enabling Intelligent Operations At A Gold MineAndr VuilleumierManaging Director
AgendaIntroductionProject SolutionBenefitsConsiderationsSummary
Who, What, Where
Geita first came into prominence as the site of a German colonial gold mine. A German gold prospector discovered the mineral in the early 1900s in the hills surrounding modern-day Geita town.
This and other discoveries triggered a gold rush in the surrounding area, attracting German and native prospectors alike. The colonial government established a mine to exploit 'Bismarck Reef'. Mining activities significantly declined, however, when Germany ceded control of its colonies to the British after their defeat in World War I.
Geita regained it's prominence in the mid to late 1990s when the Tanzanian government opened the mineral sector to foreign investment. A number of medium to large-scale mining houses, including Ashanti and Anglo American, conducted extensive exploration activities in the surrounding areas.
www.wikipedia
The most significant outcome of those activities was the construction of the Geita Gold Mine, now owned by AngloGoldAshanti. The Geita Gold Mine is Tanzania's largest gold producer.
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Following the Pattern
Two things go together production and control philosophyTo get them right, u need a SI4Add to basketApply the corporate standard
Standardise control philosophy
Better Alarming
History of production data
Real time and scheduled reporting
Expert System to improve production
Consistent Maintenance and Support
AgendaIntroductionProject SolutionBenefitsConsiderationsSummary
Spoilt for choice
WISExpert System Active FactoryInTouch SCADA Historian ArchestrA Platform V3Rockwell Allen Bradley PLC
to S U C C E S S
Inside Specification
Inside Specification
PLC ArchestrA Interface Standard DOL MotorInside Specification
Inside Specification
Inside Specification
InTouch Smart Symbols
Inside SpecificationInside
Inside
Inside
Inside
Inside
Inside
Inside
Inside
Inside
Its not inside its on top.
The Expert SystemSupervisory Control SystemTakes over the functionality of changing the setpoints from the operator & brings the mill to peak performanceThree elements are involvedFiltering of the process variables individually through a moving average & checking them against their parametersCom paring the result of each variable against the rules that are stored in the database, the result is analysed to determine wether the setpoint needs to be increased/decreasedThis is then applied to a time interval ie how quickly it needs to react to the rule to ensure the production is kept consistent
The Expert Operator is programmed to check the average of the variables & adjust the setpoint every x minutes in order to maintain peak performance, in spite of an ever changing environment!
Inside Expert System
Filtering of the process variables individually through a moving average & checking them against their parametersInside Expert System
comparing the result of each variable against the Rules that are stored in a database and the result is analyzed to determine wether the relevant setpoint needs to increased, decreased etcapplying this to a time interval ie how quicklyit needs to react to the rule
The Expert Operator is programmed to check the average of the variables & adjust the setpoint every x minutes in order to maintain peak performance, in spite of an ever changing environment.
Inside Expert System
Inside Expert System
Inside Expert System
Inside
Inside Expert System
WIS The Neighbourhood Watch
WONDERWARE INFORMATION SERVERWISLarge amounts of plant process data are aggregated into highly informative production reports tailored to AngloGold Ashanti corporate requirementsIntegrated with existing IT infrastructure and web portalsWIS has helped connect plant personnel with other non Wonderware data sources so that they can access the entire plant recordIndividual users at Geita have been assigned different views/areas that they would normally have access to
Displays include KPIsProduction reportsTrendsPublished InTouch Screens
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Geita can now get the right info at the right time to improve their plants performanceInside WIS
Inside WIS
Inside WIS
Inside WIS
Inside WIS
Inside WIS
Inside WIS
Inside WIS
AgendaIntroductionProject SolutionBenefitsConsiderationsSummary
Show Me The Money!
CHANGEOVER On a live plant!Within maintenance shutdownsProject spanned 12 months
BENEFITS Corporate standard is in placeNew Roadmap for future ProjectsState of the art Control System with best support & training infrastructureAlarming ensuring safety and logging the triggers
Perhaps the biggest benefit has been the implementation and use of the WIS so that the right information gets into the hands of the right people, at the right time, so that they can improve plant performance, even when not on site.
AgendaIntroductionProject SolutionBenefitsConsiderationsSummary
The System specification that was drawn up has been proven to be a good guidance (WW Best Practice Guide, S95, WW System Platform Checklist)Modeling, Structure & Concept must be done carefully before you startInvestigate the PLC Software for easy integration to ArchestrA (Automatic Tag Linking)Thin slice and FAT Testing with approval
Problems experienced with ArchestrA V3 caused delays with commissioning (Backup you App regularly)You must take into account that a new software release might come with teething problems
Important that Comprehensive Support Agreement is in place.
Wonderware SA team provided excellent support 24/7
911, What's Your Emergency?
AgendaIntroductionProject SolutionBenefitsConsiderationsSummary
Conclusions
WONDERWARE INFO SERVERBringing the plant into the boardroom
ARCHESTRAA new platform, sustainable for future developmentsSecurity incorporates Windows, InTouch & ArchestrA security all in oneModeling jump starts the projectIAS 3.0 SP2 new user defined objects, & UDAs and integrated graphicsPowerful field attributes moving average, alarming etcAlarming no room for error, no engineering required
INTOUCHSmart Symbols (ArchestrA graphics were not used due to teething problems)Easy & quick to build new applicationsMaintains a standard in the groupIndirect Tagging 1 data source, facilitated via ArchestrAIncorporated ActiveFactory trends to analogue pop ups, great feature, minimal engineering
HISTORIANConfigured through ArchestrA, time saving
ACTIVE FACTORYEnabled tag hierarchy
EXPERT SYSTEM Increases productivity & facilitates an automation based result as opposed to a result based on human interface
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A Light At The End Of The TunnelAt Geita gold mine in Tanzania the loss of skills at all levels through the process plant necessitated the implementation of automated control as far as possible to reduce variability and increase control expertise. The Fuzzy Logic rules can and are implemented remotely from South Africa or anywhere else, saving time, transport costs and consultation costs. The benefit of Fuzzy Logic Rules will increase in parallel with the increase in unit run time, as well as compound its improvement as variability is decreased.
Corne Lourens Metallurgical Manager, Geita Gold Mine
Q & A
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