The Referenced Architecture for Longwall Mines
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The Referenced Architecture for Longwall Mines

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Geoff Irvine, Industry Solutions Manager – from South Pacific, Rockwell Automation delivered this presentation at 2012 Longwall conference in the Hunter Valley Australia. Building on eleven years ...

Geoff Irvine, Industry Solutions Manager – from South Pacific, Rockwell Automation delivered this presentation at 2012 Longwall conference in the Hunter Valley Australia. Building on eleven years of excellence it’s rare that such a large gathering of underground coal operators come together under the one roof, providing a great opportunity to catch up with friends, industry leaders, former colleagues and longwall mining specialists.
For more information, please visit: http://www.longwallconference.com.au

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The Referenced Architecture for Longwall Mines The Referenced Architecture for Longwall Mines Presentation Transcript

  • 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 1. Rockwell Automation Overview
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Focusing on Plant-wide Automation
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2. Automation Trends in Longwall Mines
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Automation Trends in Longwall Mines 10 Shearer automation retrieved from http://www.aimex.com.au/en/product-profile/?prodId=470997, on 16 Oct 2012
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 3. Referenced Architecture for Communications
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Presentation Source Delivery Real-time Information The network is the backbone of any automation system.
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Industrial and IT Network Convergence Converged 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 16 Catalyst 3750 StackWise Switch Stack FactoryTalk Application Servers • View • Historian • AssetCentre, • Transaction Manager FactoryTalk Services Platform • Directory • Security/Audit Data Servers Gbps Link for Failover Detection Firewall (Active) Firewall (Standby) Distributed I/O DIO Levels 0–2 HMI Cell/Area #1 Redundant Star Topology Flex Links Resiliency Cell/Area #3 Bus/Star Topology Cell/Area Zones Demilitarized Zone (DMZ) Demilitarized Zone (DMZ) Enterprise Zone Levels 4 and 5 Rockwell Automation Stratix 8000 Layer 2 Access Switch Cisco ASA 5500 Cisco Catalyst Switch Industrial Zone Site Operations and Control Level 3 Remote Access Server Catalyst 6500/4500 Patch Management Terminal Services Application Mirror AV 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 #2 Ring Topology Resilient Ethernet Protocol (REP) DIO DIO
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Underground Mining Customer’s Referenced Architecture 17
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Value Solutions the Mining Referenced Architecture can bring 18 Multifunction Camera Video/Voice/Interative console 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Value Solutions the Mining Referenced Architecture can bring
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 4. PlantPAx Referenced Architecture for Process Systems
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Presentation Source Delivery Real-time Information – considering the entire system
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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 Copyright © 2012 Rockwell Automation, Inc. All rights reserved. PlantPAx Process Automation System PlantPAx is Rockwell Automation’s process automation system: Plant-wide control technologies in a DCS platform
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. PlantPAx reflects S95 architecture and organizes its components in functional areas 23
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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. Copyri24 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. 25 Integrated Architecture Builder has the validated PlantPAx sizing rules built in Control Strategy Definitions PlantPAx Boundaries & Rules Customers Application 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 5. PlantPAx Mining Solution
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. PlantPAx Mining Solution There are many control system risks in the mining industry, from technical, procurement and maintainability. Rockwell Automation can 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 predictable in 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.
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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.
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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.
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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.
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Mining Process: Transfer Element  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
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Mining Operation Information 35
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Mining Operation Information 36
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 6. Conclusion
  • Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 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