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Process control technologies have evolved over the years to meet the ever-changing demands of mining operations caused by factors ranging from grade decline to strict regulations as well as the changing workforce. The next step in this evolution needs to address this new reality where engineering efficiency and process optimization are a must, while also adding further efficiencies and visibility into energy usage and spend. PlantStruxure PES (Process Expert System) is the next generation Process Automation Systems developed to address the ever increasing demands and constrains of today’s mining and mineral processing operations. This presentation explores… § The integration control and power - making energy as an active part of the process § How PlantStruxure PES helps to streamline the engineering development for new mines or expansions § A single and simple environment - making operation and maintenance easier § A preview of the software that’s the foundation of the system
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PES: An Innovative Approach to Process Control Systems (and Energy Management) for Mining
Mining Metals and Minerals competency center
● Workforce crisis● Skills shortage
● Minerals scarcity● Extreme mining● Grade decline
Key Trends in Mining
In mining, energy can be up to 40% of the total cost of its supplies
By 2013, the demand for mining engineers is
expected to exceed supply by
Talent Strategy Advisors
Implications of Trends and Needs●Less funds available●Reduced workforce (less resources to develop in-house solutions or no core activities)
●Need to produce more with less●Minimize design time●Optimize project cost●Operating cost reduction●Maintenance cost reduction
Automation and Process Control
HybridProcess
MiningMetalsCement
F&B
The Conventional Solutions
Continuous Process
OilChemicals
Power
Manufacturing
AutomotiveMachinery
Complex ProcessLoops
Hi-AvailabilityProcess Language
DiscreetInterlocking
Electrician Language
DistributedControl (DCS)
ProgrammableController (PLC)
Industry Answer?
DistributedControl (DCS) ?
ProgrammableController (PLC) ?
Hybrid Control System(HCS)?
Process AutomationController(PAC)?
CollaborativeAutomation Systems?
●Simple to:●Design●Operate●Maintain
● Troubleshooting●Remote access●Intuitive
●Simple to modify, improve and expand ●Reuse●Online changes●Future proof technologies
●Easy interaction with other systems (MES/Energy/Instruments)
Users need a system...
...that represents a real application
CrushingCrushing
MillMill
FlotationFlotation
Homogenization Yard / Stacking
Homogenization Yard / Stacking
Water TreatmentWater Treatment
Products YardProducts Yard
Schneider MineSchneider Mine
ReclaimingReclaiming
CrushingCrushing
MillMill
FlotationFlotation
Homogenization Yard / Stacking
Homogenization Yard / Stacking
Water TreatmentWater Treatment
ReclaimingReclaiming
Products YardProducts Yard
Schneider MineSchneider Mine
The System Translates Each Mining Operation
P&ID Diagram
Application
● Model the application as it is in the real world and improve the reusability
Process
One Single Environment/Package
Supervision
System Configuration
ProcessDesign
Logic
Alarms
Concurrent Engineering● Facilitate communication about design enhancements and process adjustments
● Delegate sections of PROCESS to various stakeholders, not sections of CODE
● Tear down barriers between Maintenance and Engineering departments to get up and running fast
● Several users can work on the same libraries and applications simultaneously from different work stations
● Check-in and check-out features are managed by the system and the user is always informed about the status of the applications
Single Distributed Configuration
Object Oriented
An integrated object offers consistent functionality throughout the system
The model is open and extensible so engineers can build their own objects if needed
The system takes care of the application lifecycle, managing the changes needed throughout the plant life
Ensures consistency across your system and drives operational efficiency
Object Oriented
●Dedicated Libraries●Control Devices
● Drives, motor starters, power meters, energy consumption, etc.
●Process control ● Signal conditioning, process loop,
sequence logic, motor control, etc.
● Users can modify and/or create their own libraries
● With diagnostic and maintenance information for operators and maintenance staff
●User guides, maintenance procedures, etc.
Dedicated Process Libraries
Built-in Energy Efficiency
● Real-time power consumption
● Dedicated libraries and application templates to help reduce energy waste
● Built-in “idle state” services for equipment that can be triggered based on stoppages or other process statuses
● Combined production and energy data to generate predictive maintenance alerts for equipment to reduce energy use and downtime
A Dynamic Demo of the Software that Powers the System
TrendsTrends Energy Management
Energy Management
Intelligent Motor
Control
Intelligent Motor
Control
AdvancedProcess Control
AdvancedProcess Control
Make the most of your energy
