The Referenced Architecture for Longwall Mines

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Automation’s Referenced Architecture for Mining

IIR Longwall Mining Conference 2012

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.2

Agenda

4. PlantPAx Referenced Architecture for Process Systems

3. Referenced Architecture for Automation Communications

1. Rockwell Automation Overview

5. PlantPAx Mining Solution

6. Conclusion

2. Automation Trends in Longwall Mines


1. Rockwell Automation Overview


Leading Global provider of industrial

automation control and information

solutions• Annual Sales (FY10): $6 Billion

• World Headquarters:

Milwaukee, Wisconsin, USA

• Trading Symbol: ROK

• Employees: About 21,000

• Serving customers in 80+ countries

Rockwell Automation at a Glance


New Zealand Headquarters

Auckland

Rockwell Automation South Pacific Region

Business Profile• Annual Sales: Approx $150 Million

• 300+ Employees

• Australian Headquarters

- Melbourne (Vic)

• New Zealand Headquarters

- Auckland

Australian Headquarters

Melbourne


Our Scope of Offerings

Components & Intelligent

Motor Control

Integrated Architecture

& Information Solutions

Service & Support

Online & Phone

Training

OnSite

Repair

MRO Asset

Management

Network & Security

Safety & Energy

InSite Managed


Focusing on Plant-wide Automation


2. Automation Trends in Longwall Mines


Automation Trends in Longwall Mines

Automation Everywhere – leading to low manning or manless operation. “Safest

underground coal mine is one with nobody in the mine”

Fully automated development machines, Fully automated longwall shearers, Fully

automated roof bolting systems

New smart sensors eg detecting position and orientation on the longwall

Combining functions such as video, voice, people tracking, control systems, remote

operations, safety functions over the one network

Information needs to be delivered remotely in real time

Emergence of wireless networks underground

Automation Standards to minimise risk

9


Automation Trends in Longwall Mines

10

Shearer automation retrieved from

http://www.aimex.com.au/en/product-profile/?prodId=470997, on 16 Oct 2012


3. Referenced Architecture for Communications


Presentation

Source

Delivery

Real-time Information

The network is the backbone of any automation system.


Delivery – The importance of the Network

Ethernet is becoming the network of choice for industrial networks – many “commercially

off the shelf” products and services available. Lots of technical resources available.

Ethernet can handle large volumes of data – new smart devices typically will have an

ethernet connection that will add data traffic to the network. Every new machine will add

5-50 Ethernet nodes.

Ethernet is easily expanded/reconfigured

Ethernet is future proof – it is easily upgraded to handle the latest features/functions.

It has the capability to carry video, voice, tracking, real time control, safety, diagnostic

information over the one network backbone

13


Ethernet/IP – The importance of the right implementation of Ethernet

Standard, unmodified Ethernet using standard TCP/IP

Real-time industrial control

High performance motion (robotic applications) and safety

Time synchronization

High availability

Configuration and diagnostics

An automation network with the performance, capacity, and expandability

Connects to thousands of automation devices from both commercial and industrial

suppliers

Is the same technology used for your Enterprise network and the Internet

Is managed by Open Device Vendor’s Association (ODVA)

14


Referenced Architecture – what is it, why would you use it

A Referenced Architecture provides a template for a solution in a particular

industry/application

It provides a guideline of how to put a system together

It is tested, validated and provides design parameters

Reduce Project set up time

Avoid reinventing the wheel

Reduce cost for ongoing maintenance

15


Industrial and IT Network ConvergenceConverged Plantwide Ethernet (CPwE) Architectures

Logical framework

Industrial and IT network

convergence

Hierarchical segmentation

Scalability

Resiliency

Traffic management

Policy enforcement

Security policies

Defense-in-depth

Secure remote access

Plant

Floor

16

Catalyst 3750StackWiseSwitch Stack

FactoryTalk Application Servers• View• Historian• AssetCentre, • Transaction Manager

FactoryTalk Services Platform• Directory• Security/Audit

Data Servers

Gbps Linkfor Failover Detection

Firewall(Active)

Firewall(Standby)

Distributed I/ODIO

Levels 0–2

HMI

Cell/Area #1Redundant Star TopologyFlex Links Resiliency

Cell/Area #3Bus/Star Topology

Cell/Area Zones

Demilitarized Zone (DMZ)

Demilitarized Zone (DMZ)

Enterprise ZoneLevels 4 and 5

Rockwell AutomationStratix 8000Layer 2 Access Switch

CiscoASA 5500

CiscoCatalyst Switch

Industrial Zone Site Operations and Control

Level 3

Remote AccessServer

Catalyst6500/4500

Patch ManagementTerminal ServicesApplication MirrorAV Server

ERP, Email,

Wide Area Network

(WAN)

Network Services• DNS, DHCP, syslog server• Network and security mgmt

Drive

Controller

HMI DIO

Controller

Drive

Controller

Drive

HMI

Cell/Area #2Ring TopologyResilient Ethernet Protocol (REP)

DIODIO


Underground Mining Customer’s Referenced Architecture

17


Value Solutions the Mining Referenced Architecture can bring

18

Multifunction Camera Video/Voice/Interativeconsole allows expert in the remote operating center to advise on maintenance operation, by combining what he observes with the process system data – see Northern Lights Technologies


Value Solutions the Mining Referenced Architecture can bring


4. PlantPAx Referenced Architecture for Process Systems


Presentation

Source

Delivery

Real-time Information – considering the entire system


Plant-wide control technologies• Standards-based architecture using

Integrated Architecture components

enables multi-disciplined control

• Scalable high availability throughout

the architecture

• Extends EtherNet/IP as control

backbone

Optimized for performance in the

process industry• Characterized for performance

• Documented architectures, defined

system elements, detailed sizing rules

and application guidelines

Extended with tools and utilities• System definition and sizing tools

• Standard application components

• Deployment and configuration tools

• System health and diagnostic tools


PlantPAx Process Automation System

PlantPAx is Rockwell Automation’s process automation system:

Plant-wide control technologies in a DCS platform


PlantPAx reflects S95 architecture and organizes its

components in functional areas

23


PlantPAx System Characterization

Main goal of PlantPAx System Characterization is to provide a recommended

architecture and sizing rules to ensure optimal system performance. The characterized

system results are reflected in guidelines and tools that can be used starting early in

the design cycle to establish the correct starting architecture.

Copyri

ght ©

24

Controller wall (50 + PACs)

Distributed System (4 servers)

Centralized

System

(1 server)

OEM (L2/L3/PV+)

Virtual System

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 25

Integrated Architecture Builder has the validated

PlantPAx sizing rules built in

Control StrategyDefinitions

PlantPAx Boundaries & Rules

CustomersApplication

Process System Estimator Data Entry Dialog

Data from the Characterized System

Process Project Tree View in IAB

Sub System IO Selection Wizards

Standard IAB System View


5. PlantPAx Mining Solution


PlantPAx Mining Solution

There are many control system risks in the mining industry, from technical, procurement and maintainability. Rockwell Automationcan help you mitigate those risks through implementation of our Mining Solution -- an integrated solution, based off of the PlantPAx process automation system.

By utilizing standardized, reusable control modules, your entire system will have a consistent look and feel with common tags/descriptions. A controller centric approach and standard Add-on-Instructions (AOIs) minimizes all configuration external to the controller. Without standardization, you run the risk of software/code that can be modified. Software is only predictablein quality and outcome if all system parameters, objects and structures are rigidly enforced. Increase delivery capability and reduce risk with a complete and scalable solution.

Even with limited engineering resources, by using highly standardized methods, procedures and software structures you can reduce the risk of adding new resources. Standardization makes it much easier to train people. Allow your engineers to spend more time focused on plant and processes rather than controller code, thus increasing overall productivity.

The use of standardized modules developed for the mining industry provides you with a robust solution to meet your performance needs. The Rockwell Automation comprehensive Mining Solution reduces the amount of extra engineered coding, reducing start-up time and maintenance support cost.


Mining Solution - Benefits

Predictable and Consistent: Integrated process control system based on standardized and

reusable control modules.

Less Risk: Encapsulated domain expertise provides stronger standardization and enforces

standards.

Controller Centric: Add competency to the system, without complexity. Single entry of tags

and descriptions.

Easier Maintenance: Add new devices quickly and easily.

Improved Diagnostics and Reporting: Remove detective work from fault finding with many

options to visualize issues. Use set of pre-defined templates.


Controllers

Control through PlantPAx Add-on-Instructions

Pre-defined AOIs provide complex code in a standardized module.

Limited programming knowledge required to add new devices, (intuitive

copy & paste).

New devices added are automatically available for reporting, no additional

configuration required

Built-in support for Standard device types (Analogs,Motors, Valves etc.)

Advanced controls such as Sequences, Transfer elements (Belts, pipelines,

silos), Groups, Multi Feeder Control (MFC)

Simulation software (Basic – Advanced) is available inside the controller,

each device configured separately. Ideal for training centers.


Controllers

Controller initiates all Data Logging (Alarms, Events,Audit Trails, Production)

Utilizing CIP Technology, add the SQL Database asLogix I/O (SQX). Server SQX

services allowing SQL to be populated directly by Logix

Increased Server / Network Failure Tolerance by buffering records in the controller.

Time Stamp at Source ( Logix Controller Time – GPS synchronized). Ensures event

Sequence integrity.


HMI User Controls –Faceplates and symbols

Utilizes pre-defined faceplates . Direct connection to

ControlLogix AOI, MS-SQL database, Intelligent Devices. Single

packet AOI read –Fast Update speed (100ms ), reduce Network

Traffic

Provides user access to: Live Data, Configuration, Diagnostics,

Alarms, Events & Audit Trails, Documentation


Field Device Integration

Defined as the attachment of instruments, discrete devices and power

components via a smart network

Networks: ProfibusPA, Fieldbus Foundation, DeviceNet, EtherNet/IP,

ControlNet


Field Device Integration

Integration of both intelligent and non-intelligent control devices into the system

using generic type AOIs

Leverages the added diagnostics and functionality of intelligent devices via the

use of FDT/DTM technology

Allows a DTM to be launched directly from both the HMI and RSLogix

environments for intelligent devices such as Ethernet/IP instruments, E3

Overloads and Powerflex VFDs


Mining Process: Transfer Element

34

Material control for Conveyor belts

Belt loading and profiling

Gap Control

Product batching and mixing control

Calculated load comparison against a known reference value

Totalization of Product volumes and types


Mining Operation Information

35


Mining Operation Information

36


6. Conclusion


Conclusion

Take advantage of Referenced Architectures to lessen any risk of the automation/process

system causing downtime to the longwall operation

The Networking Referenced Architectures provide a basis for increased productivity by

combining video, voice, tracking, automation and safety on the one system

The PlantPAx Referenced Architecture provides a “characterised” tested system that

provides for optimising longwall operations

The PlantPAx Mining Solution provides a system that lessens the risk of system

additions/changes disrupting production, as it has the site standards encapsulated in the

system. It also allows for faster startups of new longwall facilities, and faster

changeovers to exisiting operations

38

The Referenced Architecture for Longwall Mines

Business

Transcript of The Referenced Architecture for Longwall Mines