Customer Day, 22nd May 2017, Tehran

Creating value with MineOptimize

Optimization, visibility, agility and availability
Yousef Mohammadi, Javad Pourjafar, Martin Knabenhans
Creating value with ABB Ability MineOptimize Applications
Standardized and proven application building blocks

MineOptimize – Process Control

– Reduce operation errors, improve fault finding, enable collaboration between disciplines

MineOptimize – Power Control

– Monitor and mange energy distribution and consumption

MineOptimize – Advanced Process Control

– Improve process performance and yield, reduce energy cost

MineOptimize – Condition Monitoring & Asset Management

– Improve availability, reliability and maintenance procedures

MineOptimize – Integrated Mine Operation

– Scheduling, Dispatch and Fleet Management
– Real Time planning and agility

MineOptimize – Information Management

– Create visibility to make the right decisions

May 18, 2017 Slide 2

MineOptimize
ABB Ability – MineOptimize (MO)
Integrated value chain from pit to port

Hoist, Ventilation, Dispatching & Stockyard Electrification

Dewatering, APC Scheduling Control Solutions

Wireless Grinding, GMD, Condition

Solutions RMD, APC Monitoring

Drives Central Control Energy Substation

Solutions Room Management Control

Ship Load & Flotation, APC, Conveyor Belt

Unload Control Instrumentation Control

High levels of visibility across operations

May 18, 2017 Slide 4

MineOptimize Process Control – MO-PC
Consistent, proven, flexible operation concept

The MineOptimize way Conveying systems,

Object oriented, Standard modules for
stacking, reclaiming,
parameterized all basic mining
ship loading and
Increases standardization, solutions applications
unloading
functionality and quality of process
control software over the complete
life cycle MineOptimize

The traditional way

• Different areas with different operation

concept
Reduced risk – proven Operator training
• Not reusable control software makes Mining-specific
solution and system with built in
hard to maintain and adapt faceplates and GUI’s
behavior simulation

May 18, 2017 Slide 5

System 800xA: the way forward
… today often islands of automation

No overview
No integration
No ergonomics
Unorganized
Low level of situation awareness

May 18, 2017 Slide 6

System 800xA: the way forward
from today to tomorrow … now
System 800xA

PLC
PLC, SCADA
PLC, Panel
PLC

PLC, SCADA
PLC
PLC, SCADA PLC, Panel

DCS 3 PLC DCS 3 PLC, SCADA

PLC

PLC

DCS 2 DCS 1 PLC

PLC
PLC, Scada

DCS 2 PLC, SCADA

DCS 1
Plantwide information access, plantwide integration, plantwide optimization, plantwide collaboration

May 18, 2017 Slide 7

System 800xA: the way forward
from today to tomorrow … now

System 800xA
PLC
PLC, SCADA
PLC, Panel
PLC

PLC, SCADA
PLC

DCS 3

PLC

DCS 2 PLC, SCADA

DCS 1
Plantwide information access, plantwide integration, plantwide optimization, plantwide collaboration

May 18, 2017 Slide 8

System 800xA: the way forward
from today to tomorrow … now
System 800xA

PLC, SCADA PLC, Panel

PLC

PLC DCS 3 PLC, SCADA

PLC

DCS 2 DCS 1 PLC PLC, Scada

Plantwide information access, plantwide integration, plantwide optimization, plantwide collaboration

May 18, 2017 Slide 9

System 800xA: the way forward
EOW – Extended Operator Workplace – tomorrow is now

All information integrated at the finger tip

Personalized overview
Advanced ergonomics, silent, tidy
Organized and motivating, human centric
High level of situation awareness

May 18, 2017 Slide 10

System 800xA : the power of integration
One common automation platform
ERP Knowledge Expert
Engineering Information Asset Device Operations & Remote Connectivity Smart Energy Manager System
Base Management Optimization Management Engineering Diagnostics (e.g. Ellipse) Client Management (PIMS) (APC)

AC800M MOD300 Harmony DCI Melody PLC Safety Other Field

IEDs
integration Systems OPC Devices

May 18, 2017 Slide 11

System 800xA : the power of integration
Integrating equipment, systems and people

• An infrastructure that can represent all

the assets
• Embed all applications and systems
• Share information without barriers
• Bring teams together and get the best
from all teams
• Empower people to perform their best

May 18, 2017 Slide 12

Solutions for operation
Improving operator effectiveness thru integrated information and process optimization
Improving Operator Effectiveness
…through integrated information

Integrated operations Field Device and Documentation

Asset Optimization Operator Logs
– Seamlessly integrate information regardless of source CMMS Integration History
Reports
– Operation, engineering and maintenance from any place at any time
High performance user interface Trends
– Ability to manage views dynamically, effectively and context related
– Advanced alarm management
– Enables collaboration
Model Alarm Management
Integrated engineering Object Graphics, Faceplates

– Enter configuration only once

– Multi user engineering CCTV / Video

– Object type library based Control & IO

Libraries
Operator competency APC

– Operator training environment using same system, operator displays and

Real Object
control strategies

May 18, 2017 Slide 14

System 800xA: the power of integration
…access of any information through context menu

Asset Monitoring Electrical & Field

Information
Device Management
Management

Report
Loop Drawings

Interlock Status
Panel
Drawings
Control Alarm & Event

May 18, 2017 Slide 15

Improving Operator Effectiveness
…through Ability to manage views dynamically & effectively

– Group presenting the status of connected consumers. Example: Pre-warning for a drive. Operator may navigate from the group to the
consumer faceplate of the drive causing the problem by using the dynamic link button.
– The consumer faceplate shows all possible causes for disturbances. Example: Temperature warning H1>75°. Navigation to the signal
faceplate or to the PCC interlock viewer is possible.
– The PCC viewer shows the interlock types and status of all connected signals. In the example H1 is defined as Equipment Start-, and
H2 as safety interlock.

May 18, 2017 Slide 16

Improving Operator Effectiveness
…through seamlessly integrated information regardless of source

ABB MCC UMC100 integration to 800xA

Intelligent devices provide additional information to improve the
availability and operational excellence

Remote monitoring, helps experts to analyze and configure the

device form any place at any time

Early warnings, allow to act immediately and prevent trips and

shutdowns

On-line, historic and statistic information is the key for better asset
management and continues improvement of the productivity

May 18, 2017 Slide 17

Improving Operator Effectiveness
…context related access to 3rd party systems and data

Documents stored in 800xA

Documents stored in 3rd party
documentation system
Tag oriented search of documents
related to 800xA object

May 18, 2017 Slide 18

Improving Operator Effectiveness
…through advanced model based process control (APC)

Multivariable Controller: uses several measurements to

adjust several actuators, while accounting for the
interactions between them
Used to increase efficiency at a given quality, making the
process more efficient, cost effective and reliable

May 18, 2017 Slide 19

Improving Operator Effectiveness
…through Advance Alarm Management

– 20 most frequent alarms

– 20 alarms that were active for longest time
– Alarm rate
– Average time to acknowledge
– Alarm severity distribution
– Enables a starting point for alarm rationalization
– Analysis of “worst cases”
– Allows for continuous analysis and optimization
– Promotes collaboration between operators and
process/system engineers

May 18, 2017 Slide 20

Capture DCS test check results directly on the faceplate
Mineral Library commissioning check extension library

Commissioning tab
The Minerals Library elements include an
additional commissioning tab in their
Faceplate. This tab is can be activated during
the commissioning and will allow engineers or
operators to capture and track commissioning
tests directly within 800xA in real time.
Advantage:
- Reliable, fast and easy to capture the
commissioning status while performing the
checks
- Centralized data handling and simultaneous
multi-user editing
- Traceable and quality control (including
time stamp and user information)
- Specific test cases per control objects
- Adjustable to project specific test cases

May 18, 2017 Slide 21

Integration with EBase
Test cases are prepared in EBase and exported to 800xA

Interface to EBase
The test cases are tailored to the different
types of control objects within EBase. This test
cases will guide the engineers through the
testing and make sure that all related signals
and functions are getting tested.
The current state of the commissioning can be
captured with a single mouse click and
uploaded to EBase.
In the database of EBase the commissioning
result and progress over time is stored directly
on the objects used for the automation and
electrical planning.

May 18, 2017 Slide 22

Improving Operator Effectiveness
…through modern control room concepts – EOW

May 18, 2017 Slide 23

Solution for Engineering
Cost efficient integrated electrical and automation hardware and software engineering
Overview

Key Technologies Key Competencies Key Services

– Automation Platform 800xA – Bid & proposal including sales support – Inspections
(Hardware & Software) during FEED and Bid – Factory Acceptance Tests
– Electrical Control System Integration – Site assessments – System Integration Tests
– Minerals Library – System engineering including CAPEX – Performance Tests
– LV Switchgears & MCCs and OPEX Optimization on System
Level – Commissioning
– Auxiliary Power Distribution / UPS – Troubleshooting & Site Support
– Developing / Coaching and Consulting
– Instrumentation (incl. CCTV) on Tools & Procesures
– Field Networks – Overall Technical Project Management
– Asset Management / Lead Engineering
– Communication Networks – Conceptual design of systems
– Basic and Detail Engineering
– 3rd Party interface definition,
coordination and verification
– Vast Industry know-how

May 18, 2017 Slide 25

Engineering Process Bid & Proposal Basic Engineering Ø Documents
q Hardware
v Software
Conceptual & Basic design

Owner Input data such as: Contract / plant layout / P&ID

Civil & process EPCM
General Contractor Motor-, load- & instrument list, international-, local, Freeport standards
Machine OEM

ABB EC&I Project Standards

Approval process
& guidelines
Ø Basic data for electrical Studies
Design
Project management

equipment
Ø Interface concept specifications
Ø Overall Single Line Diagram Ø Power system studies
Ø Power distribution concept Ø Power quality studies Ø High voltage
Ø Protection concept (power factor correction Ø Medium voltage
Ø Interlocking concept and harmonic filter) Ø Low voltage & MCC
Ø Lighting & sockets Ø Communication networks Ø Emergency supply
Ø Lightning & earthing Ø Energy efficiency Ø Drive systems
Ø Control voltage Ø Process optimization Ø Motors
Ø Cable concept Ø Design Review Ø Instrumentation
Ø Installation Ø Seismic studies Ø Control system
Ø Plant control configuration Ø etc. Ø CCTV & Com Network
Ø Operation concept Ø Fire & safety
Ø etc. Ø Cables & installation
Ø E-House
Ø etc

Slide 26
May 18, 2017 Freeport El Abra
Conceptual & Basic design
Drive Collaboration Discipline Design Item Criteria
- Fieldbus Harmonization
- Footprint
- Performance
Relay HW Interface
MV Engineering - Interoperability Plant Operation
LV Engineering - Access to device parametrization Concept
Drives Engineering and advanced diagnostics
- Fast Root Cause Analysis
Relay SW Interface - Efficient Operation
- Maintenance Interface Concept
- Engineering Tools
Drives Engineering GMD System
- Footprint
- Wiring Cost
Junction Boxes - Ease of Maintenance
HMI Specification
Rules & - Max cable length
Regulations Infrastructure Engineering
- Shared HW Infrastrucutre
Communication
- Common Technology Programming
Networks
- Performance Specification
Plant Layout Cross- Discipline collaboration
Hardware
Specification

Basic Design
Customer
System
Guidelines
Architecture

May 18, 2017 Slide 27 Freeport El Abra

Conceptual & Basic design
Drive Collaboration - HW Interface Optimization

– Enable capabiltities of intelligent

devices
– Full information transparency
– Access to diagnostic data
– Access to fault recorders
– Remote monitoring
– Remote configuration
– Enable proactive maintenance
– Improved availability
– Improved safety
– Continuous improvement
– Operational excellence

May 18, 2017 Slide 28 Freeport El Abra

Conceptual & Basic design
Drive Collaboration - SW Interface Optimization
Proper integration…
100%
– …ensures that all information from and to
the device is available where needed
– …allows (remote) diagnostic,
100% configuration & maintenance

100%

– Bad integration reduces the benefit of

40% 30% intelligent devices as the information does
not arrive where needed

50%

100%

May 18, 2017 Slide 29 Freeport El Abra

Automation Engineering
Drive Collaboration - Sub-PLC integration
Operation Engineering Remote Support /Eng / Maint

e.g.ABB Remote
firewall services
router
Parametrization

Engineering
Disadvantages:
Advantages:

Remote
Access
§§ Exchanged signals
No additional need to be mapped on both sides (engineering efforts)
mapping
Data Link

§
§
Limited acces
Full access to diagnostic
to diagnostic data
data
§ Limited access to device parametrization
§ Full access to to device parametrization
Diagnositc

§ Limited remote troubleshooting possibilities

Device

3rd party PLC § Remote troubleshooting down to the device

§ Different Engineering tools / Different knowledge Base required
§ Consistency in operation
§ Reduced operation / alarming consistency
§ Consistency in abnormal situation management
§ Change Managament requires changes on multiple levels
§
§
Unified Engineering
Additional Tools
control mode required (PLC mode)
§ Inconsistent interlock indication, duplicated programming required

May 18, 2017 Slide 30 Freeport El Abra

Conceptual & Basic design
Drive Collaboration - Sub-PLC integration
Operation Engineering Remote Support /Eng / Maint

e.g.ABB Remote
firewall services
router
Parametrization

Engineering
Disadvantages:

Remote
Access
§ Exchanged signals need to be mapped on both sides (engineering efforts)
Data Link

§ Limited acces to diagnostic data

§ Limited access to device parametrization
Limited remote troubleshooting possibilities
Diagnositc

§
Device

3rd party PLC

§ Different Engineering tools / Different knowledge Base required
§ Reduced operation / alarming consistency
§ Change Managament requires changes on multiple levels
§ Additional control mode required (PLC mode)
§ Inconsistent interlock indication, duplicated programming required

May 18, 2017 Slide 31 Freeport El Abra

Automation Engineering
Drive Collaboration - Sub-PLC integration
Operation Engineering Remote Support /Eng / Maint

e.g.ABB Remote
firewall services
router

Engineering
Advantages:

Remote
Access
No additional mapping
Data Link

§
3rd party PLC
§ Full access to diagnostic data
§ Full access to to device parametrization
§ Remote troubleshooting down to the device
§ Consistency in operation
§ Consistency in abnormal situation management
§ Unified Engineering Tools

May 18, 2017 Slide 32 Freeport El Abra

Conceptual & Basic design
Generating Value through early collaboration focus

People Systems – Know-How

– Technology
– Platform

Basic Design

Equipment

May 18, 2017 Slide 33 Freeport El Abra

Value of collaborative process automation

Potential improvements in a medium-sized plant

– Reduce unscheduled downtime by 40-50%
– Improve energy efficiency by 15-20%

Value of information

Value of information
– Increase asset utilization up to 10%
– Boost personnel productivity up to 10%

Source: ARC Advisory Group – CPAS 2.0

Time People collaborating

The value of information is The value of information is
A collaborative process automation enables a culture
inversely proportional to the directly proportional to the
change required to capitalize on unforeseen time until it can be actionable. number of people
opportunities collaborating.

May 18, 2017 Slide 34

3BSE068147 en J
Engineering Process
Manu- Ø Documents
Detail Engineering FAT
facturing q Hardware
v Software
Detail Engineering

Owner
Civil & process EPCM Project rules & Design
Input data
General Contractor guidelines specifications

HW Factory acceptance tests

Machine OEM

ABB EC&I
EC&I hardware Cable & infrastructure
Interface and wiring
engineering engineering and
engineering
Project management

and supply supply

q HV and MV ØSingle line diagram Ø Cable List Ø Cable dimensioning

q LV and MCC ØPanel drawings Ø Loop diagrams Ø Cable routing layout
q Emergency supply ØHookup drawings Ø Interconnection Ø Cable pulling lists
q Drive systems vProduct software diagrams (Consumer Ø Installation drawings
q Motors ØProduct manuals circuits) Ø Erection manuals
q Instrumentation ØInstallation and
q Control system commissioning q Cables
q CCTV & Com manuals q Installation equipment
Network
q Fire & safety

Slide 35
May 18, 2017 Freeport El Abra
Engineering Process
Manu- Ø Documents
Detail Engineering FAT
facturing q Hardware
v Software
Process control SW and device integration

Owner
Civil & process EPCM Project rules & Design
Input data Functional process description
General Contractor guidelines specifications

SW Factory acceptance tests

Machine OEM

ABB EC&I
EC&I product
Interface and wiring
engineering
engineering
Project management

and supply

1)
800xA device integration libraries Minerals 800xA application library

Integrated 800xA process control and power automation

software engineering
v Process and electrical control software v Integrated E&I device monitoring and configuration
v HMI displays (process and electrical) v Integrated plant documentation
v Alarms, events, audit trails v Remote operation, maintenance and data access
v Historical data, trending
1)
Slide 36 800xA = ABB’s Process control systems
May 18, 2017 Freeport El Abra
Integrated EC&I engineering
Engineering has impact on operation & maintenance

• Engineering
• Electrical, control & instrumentation
engineering in one tool
• Management of changes and external data
import
• Wizards for all major engineering tasks
• Template based engineering
• Automatic production of drawings
• Export of control application to DCS

• Operation
• Common, consistent operation concept
• Fast resolving of abnormal situations
• Properly designed A&E implementation

• Maintenance
• On-line access to EC&I engineering data
• Always up to date documentation
• Synchronization of changes made in the DCS
to EC&I engineering tool

May 18, 2017 Slide 37

Integrated EC&I engineering
Engineering Base CAE tasks / functions

• Plant wide CAE tool for electrical &

instrumentation
• Import of external data
• Revision handling and compare
• Data base for all EC&I equipment and
functions
• Catalogs for EC&I equipment's and cables
• Automatic drawing generation
• Parameterization of 800xA process control
application
• Integration to the 800xA automation system
• Available on site for maintenance

May 18, 2017 Slide 38

Integrated EC&I engineering
Engineering Base CAE documents

• EC&I drawings & documents

• Single line
• Panel layout and wiring
• Interconnection and loop’s
• P&I and hookup
• Communication network
• Part list
• Cable list
• Terminal list
• IO board signal labels
• Signal and loop setting lists

May 18, 2017 Slide 39

Integrated EC&I engineering
Common Plant CAE Tool
Contract / plant layout / P&ID / Functional process
description / Motor-, load- & instrument lists, international-,
local, customer rules

EBase electrical and instrumentation CAE tool with full

integration into 800xA control system engineering
Project rules
Design specifications
guide lines
Interface and wiring Cable & infrastructure
EC&I engineering engineering engineering

800xA device BU Minerals 800xA

integration libraries application library
800xA control system engineering
Slide 40

May 18, 2017 Freeport El Abra

Integrated EC&I engineering
Common plant CAE tool – 800xA Integration

Engineering Base CAE tool 800xA control system engineering

EBase - 800xA
synchronization
May 18, 2017 Slide 41
Integrated EC&I engineering
New or modified
Basic Workflow load and
Import & Compare
instrumentation list

Loop / wiring
drawings
Loop / Typical copy
wiring Automatic drawing
typicals generation Cable list

I/O cabinet
I/O cabinet drawings
templates
I/O allocation

I/O list and labels

800xA
Minerals 800xA DCS 800xA / Control
integration application export Diagram Editor
library

May 18, 2017 Slide 42 Freeport El Abra

Integrated EC&I engineering
New or modified
Basic Workflow load and
Import & Compare
instrumentation list

Loop / wiring
drawings
Electrical &
Loop / Typical copy Cable
wiring Automatic drawing
typicals generation Cable list
engineering

I/O cabinet
I/O drawings
cabinet I/O allocation Panel
templates manufacturing
I/O list and labels

800xA
Minerals
& device 800xA DCS 800xA / Control
integration application export Diagram Editor
800xA
library

May 18, 2017 Slide 43 Freeport El Abra

Minerals Library
Enhancing Engineering Efficiency

– Intelligent Objects talking to each other

– One connection approach
– > 90% of typical mining functionality fully parametrized
– Enables CAE based engineering

May 18, 2017 Slide 44 Freeport El Abra

Integrated EC&I engineering
Benefits / summary / message

• Engineering has an impact on CAPEX and OPEX cost

• A modern CAE EC&I tool properly integrated into the plants DCS system improves
the engineering quality & consistency and reduces the implementation time
• 800xA application and device integration library enables application structuring
and parameterization already in CAE tool
• FAT is efficient because of the Minerals Library built in simulation functions
• Operation benefits from consistent template and library based engineering as it
uniforms the operation concepts, fault finding procedures and alarm messages
• Maintenance profits form on-line availability of drawings, design and equipment
specifications
• Engineering data and tool is not disconnected once deployed to site, it remains up
to date while the enterprise evolves

May 18, 2017 Slide 45

Minerals Library
Added Value throughout the plant lifecycle

Engineering Operation Maintenance

– Efficient software design – Fast commissioning and early “ready – Detailed diagnosis of integrated
– Object Oriented Approach for operation” devices
– Embedded into CAE tools to allow for – Reduced risk (through pre-tested – Linked documentation
mass generation of code modules) (fast access to drawings / manuals)
– Structured application design, with – Common, flexible operation concept – Up-to-date documentation
high consistencies over the complete – Best in class operation – CMMS integration
plant – Fast detection and resolving of any – Remote monitoring & configuration
– Built-in process know-how process disturbance – Simple and safe upgrades
– Take over data from other EC&I – Consistent alarm messages – 24/7 support
engineering phases – Built-In framework of “Abnormal – Globally distributed team of dedicated
– Built-In Simulation Situation Management” (ASM) resources for on site support
– Reduce FAT time

May 18, 2017 Slide 46

Flexible I/O Solutions
I/O’s impact on automation projects

Traditional “Controller centric” architecture is

inflexible
Field wiring schedule drives need for
marshalling cabinets
Costly late changes are inevitable:
– Changes in control logic
– Updates to OEM equipment
– Capacity balancing / partitioning
– New equipment being added
Traditional I/O with Marshalling
– Signal type changes Cabinets

Traditional I/O design creates dependencies

May 18, 2017 Slide 47

Flexible I/O Solutions
Decoupling the tasks

Traditional Approach – Dependency Driven

– Dependencies drive a ‘serial’ approach.
– Project information is supplied to automation
supplier
– Hardware design is frozen, application
programming begins
– Late changes create costly change orders

New Approach with Decoupled, Parallel Tasks

– Configuration and hardware build start

Schedule and together
cost savings – Later hardware design freeze means changes
have less impact.
– Activities can be done in parallel reducing
overall project schedule

May 18, 2017 Slide 48

Solution for collaboration
Promote collaboration through integrated plant systems and applications
Integration of automation & electrical devices
Example separate process and power systems

organizational
different engineering, barriers
operation and maintenance

separate system

separate information many protocols

management

limited access
between systems local tools

May 18, 2017 Slide 50

Integration of automation & electrical devices
One single ABB System 800xA

total plant 800xA workplace common engineering,

integration with operation and
System 800xA maintenance

system servers
system network common mining
and minerals
common system application library
integration based on architecture AC800 M common information
open standards controller
management
field bus network IEC 61850
devices for
instrumentation,
drives, low and
high voltage
common access to
complete automation
diagnostic &
and electrical portfolio
configuration of
from ABB
intelligent devices

Integrated process and power automation

May 18, 2017 Slide 51

Integration of automation & electrical devices
ABB Mining and Cement one system approach

extended operator Engineering, training & process production headquarter

workplace maintenance optimization management ERP and business systems

ECS, ISA-95, OPC…

corporate network
firewall
router mobile/remote operation
engineering and maintenance automation system network

high integrity control wireless

system servers safety shutdown communication
fire and gas
AC800 M
process controller sub system controller
AC800 M

Ship/train loading - automatic stockpile grinding

unloading system loading, unloading drive systems
transport
main process and power control 800xA based integrated sub systems

May 18, 2017 Slide 52

Substations, drives and LV switchgear
Device integration into 800xA & Minerals Library

Totally integrated into 800xA process control system

Reduced network infrastructure
Common Servers
Remote operation
Seamless remote monitoring & configuration
Integrated Documentation
Reduced spare parts

May 18, 2017 Slide 53

800xA device integration libraries
… but only if they are properly integrated

Proper integration Bad integration

Ensures that all information from and to the device is available Reduces the benefit of intelligent devices as the information
where needed does not arrive where needed
Allows (remote) diagnostic, configuration and maintenance Not all protocols/fieldbuses allow same quality of integration
Knowhow is key to success

40% 30%
100%

100% 50%

100% 100%

May 18, 2017 Slide 54

Substations, drives and LV switchgear
IEC 61850 integration into 800xA & Minerals Library

May 18, 2017 Slide 55

Integrated Process Control for Open Pit Mining
Stockyard Managment and Remote Operation

SYMS
– Inventory and ERP connectivity
– Quality
– 2D / 3D
Automatic Yard Machine Operation
Collision Protection
Remote Control

May 18, 2017 Slide 56

System 800xA: the power of integration
CMMS System integration (SAP, MAXIMO, Ventyx)

Submit fault report from 800xA object to

maintenance system
Create work order
Take over PCS tag, description and fault reason

May 18, 2017 Slide 57

System 800xA: the power of integration
CMMS System integration (SAP, MAXIMO, Ventyx)

View pending work orders

Context related from device or group level

May 18, 2017 Slide 58

MineOptimize Advanced Process Control – MO-APC
Process optimization according to ore properties

The MineOptimize way Model predictive

Real time ore analyzer Real time operations
control engine
detects changes to reports changes in
integrated into
ore grade ore properties
control system
Higher equipment utilization, increased
recovery and lower energy consumption
MineOptimize

The traditional way

• No information on upstream
downstream impact Predictive
Plant react to ore
More metal ore is adjustments made to
• Can’t prioritize significant data volumes variability ahead of
recovered grinding, flotation or
time
other equipment

May 18, 2017 Slide 59

Advanced Process Control for minerals processing

Your challenges Our solution

Need for optimal productivity Advanced Process Control solution providing you with modern
Need for reduced energy consumption tools, such as Model Predictive Control, graphical program editor
etc.
Shift-to-shift variations
Variable ore characteristics

May 18, 2017 Slide 60

Advanced Process Control for minerals processing
Get ore properties from MineMarket – Stockyard Models

Use ore properties to

improve APC models

May 18, 2017 Slide 61

Advanced Process Control for minerals processing
Store ore properties to MineMarket – Stockyard Models

800xA collects, aggregates, and sends

the stacking information as series of
transactions to MineMarket (e.g., tons,
position, and grade) via.

MineMarket stores this to the cubic-meter

resolution, allowing users to visualize
quantity and quality in any section of the
stockpile with 2D and 3D views.

May 18, 2017 Slide 62

Your benefit
Stabilize then optimize

May 18, 2017 Slide 63

Optimal control of ore processing plants

Production depends on
– Recovery
– Throughput
APC increases recovery by
– Controlling particle size in grinding
– Controlling froth properties in flotation
APC increases throughput by
– Driving mills to their design constraints in power and torque
– Keeping flotation circuit level stable at flow constraints

May 18, 2017 Slide 64

Grinding circuit optimization
Typical variables
Pulp quality
Ore feed Ore size To processing
plant
Cyclone
Returned pebbles

Feed water Fill indicator

Fill indicator
Mill
Mill Mill speed
Power
Mill speed
Power

Screen

Legend:
Sump water
Manipulated variables
Controlled variables
Measured disturbances Sump
Density

May 18, 2017 Slide 65

Advance process control for grinding
Particle size variability reduced by 50%

Features Benefits
Mill load and throughput optimization Optimal output at given product quality
Particle size control Better performance of downstream processes due to better
Support for various mill types (AG, SAG, ball etc.) and circuit control of the grinding process
configurations Increased mill liner lifetime

May 18, 2017 Slide 66

Flotation circuit optimization

recirculating flow
AT

BL031 FA301 FA302 FA303 FA304 FA305

AT FT
feed AT
tailings

Legend:
AT FT
air addition

AT AT FT
froth level change
hydro-
reagent addition FA104 FA103 FA101 FA102 cyclone

AT X-ray analyzer

FT volume flow meter AT regrinding

concentrate mill

May 18, 2017 Slide 67

Advance process control for Flotation

Features Benefits
Module for coordinated cell level control Improved circuit control to optimize separation of the product
Module for overall circuit control from gangue
Increased recovery due to tighter control of frothing conditions
Optimum reagent consumption

May 18, 2017 Slide 68

APC for Phosphate Flotation

Target: Minimize concentrate grade in tailings (A) while keeping the final concentrate at optimized level (B)

Available measurements
– Phosphate concentrate measurement with 1h delay
– Feed to circuit
– Temperature
A – pH
Actuators:
– Froth depth levels of each cell
– Air to each cells
– Reagents (various points)
– Additional water (various points)
Disturbances:
– Incoming material properties
– Amount of recycled water
B
– Temperature affecting viscosity

May 18, 2017 Slide 69

APC for Phosphate Flotation

Idea: Soft sensor based on ABB Ability Advanced Process Control using real time data to estimate the concentrate grade in tailings (A)
which is available with 1h delay only

- 1h delayed concentrate measurment

- Soft sensor real time estimate
B

May 18, 2017 Slide 70

APC for Phosphate Flotation

Idea: Soft sensor based control Scheme

Production Targets
measurements
APC Soft
sensor
APC
A Add. measurements
Optimal Actions

Estimated benefits:
Disturbance reduction through Soft
Sensor and APC leading to more stable
and higher recovery (below actual
status, before optimization)
B

May 18, 2017 Slide 71

Mine ventilation system
Current situation vs ABB Ventilation on Demand

Current situation ABB Ventilation on Demand

Limited use of sensors and feedback control Support for time schedules, blast, fire handling, gate control,
Air quality is based on feelings rather than measurements local control and maintenance functions.
Demand driven ventilation based on estimation, regulations and Air flow demand is calculated from machine location, air quality
precence of vehicles sensors or manual settings.

May 18, 2017 Slide 72

Advance process control for ventilation

Total fa n powers
1700

The total fan power was decreased by 50 % optimizing the the fans 1600

speeds keeping all current six air flows the same. 1500

The fan power was inreased again then the air flows in cell 2 and 1400

access ramp 1 were increased to evaluate control

1300

kW
1200

1100

1000

900

800
12 12.5 13 13.5 14 14.5 15 15.5 16
t (decimal)

Fan speeds
110

100

90

80

70

%
60
1
2
50
3
4
40
5
6
30
7

20
12 12.5 13 13.5 14 14.5 15 15.5 16
t (decimal)

May 18, 2017 Slide 73

Summary
MineOptimize – Advanced Process Control for grinding

Typical values we deliver to customer

– Increased recovery
– Reduced quality variability
– Energy savings
– Increased equipment lifetime
– Operational discipline

May 18, 2017 Slide 74

MineOptimize Condition Monitoring & Asset Managment
React to asset condition in real time

The MineOptimize way Asset management Predictive

Asset monitor
integrated into maintenance alarm
detects condition
control system is triggered
Reduce maintenance costs while improve
equipment reliability and reduce
unplanned shut-downs
MineOptimize

The traditional way

• Reactive maintenance
• High operating costs
• Unexpected breakdown of critical Maintenance and
Work order with site
assets Reduces losses due operation responds
maintenance crew is
• Catastrophic impact on production to equipment failure ahead to reduce
raised automatically
targets failure risk

May 18, 2017 Slide 75

Maintenance practices
Different philosophies for different assets

Cost of maintenance Asset categorization

10x
5% – Predictive (continuous)
Critical

5x – Condition based (periodic)

25% Essential

1x – Time based (preventive)

30% Important
Predictive Preventive Corrective
– Reactive
Corrective maintenance can cost ten times as much as a
predictive maintenance strategy. 40% Basic

Reactive – Fix on failure

Preventive – Maintain on schedule Reliability centered maintenance – strategy based on
Predictive – Maintain when condition detected the role of the asset, its safety & criticality
Source: ARC Advisory Group

May 18, 2017 Slide 76

Plant Asset Management / Enterprise Asset Managment
3 Levels

Enterprise Asset Management and CMMS with integration into

800xA Control System
Plant Asset Management fully imbedded into of 800xA control
system
Smart and Intelligent devices connected to automate real time
data collection as much as possible

May 18, 2017 Slide 77

Continuous improvement of maintenance process

AssetVista
Equipment Components
Support the decision-making process
Data Source

Process
Data 1
“on/offline” Transform
data into
information

1 2
History
Data Engineering Evaluation and Planning and
Maintenance optimization execution

Expert
3
Monitoring Transform
System info into
knowledge

5 5 4

Maintenance Strategy

May 18, 2017 Slide 78

Scalable Plant Asset Management
Small footprint pre designed Condition Monitors

1. Essentials Package Equipment

Implement dashboards for a holistic view of
conveyor health and its sub-components. 3. Rotating Machine Package
Integrate existing condition
monitoring systems, break up
Electrical Automation Mechanical information silos

Transformer Control Loop Gearbox

Motor IO Module Belt

2. Automation and Electrical Package
Make use of the technology already
installed, improve the return of
investment - ROI 4. Production Equipment Package
Drive Controller Add new monitoring solutions,
continuous improvement

May 18, 2017 Slide 79

Speed up decision making process

Decision-making is carried out The condition of the conveyor belt is the

based on the criticality of the combination of sub conditions of its
components relative to the components based on hierarchical diagram
parent equipment

Component condition
based on the
monitored failure
modes

The easy root cause

analysis enables the
reduction of the mean
time to repair – MTTR

Intuitive navigation, seamless integration with EAM

May 18, 2017 Slide 80

Plant Asset Management
Example Asset Monitor 1/2

AssetVista consulting: AssetVista maintenance engineering AssetVista automation engineering

– Maintenance requirement – FTA development and condition – Evaluate condition monitoring
– Maintenance process monitoring assignment capability (technology)
– Maintenance end user – Evaluate required inputs and data – Follow up device integration for
sources better serve maintenance and not
– Develop condition monitoring only control
algorithms

May 18, 2017 Slide 81

Plant Asset Management
Example Asset Monitor 2/2

AssetVista engineering: Practical result of AO with maintenance

– Development of asset monitor or AssetVista engineering: engineering:
assignment of a existing AssetVista – Setup dashboards based on – Condition based maintenance, reduced
asset monitor criticality, area route inspection and reduce reactive
– Map of input data – Pareto for most activated maintenance.
failures – Improvement of instrumentation
– Pareto for devices with more technicians knowledge concerning to
alerts positioners
– Prevented losses

May 18, 2017 Slide 82

Plant Asset Management
Example Asset Monitor Maintenance Inspection Workflow

– Overview of all devices from same family

– Only important maintenance alerts
– Cross reference analysis device and process
– Threshold limits exposed outside the DTM
– Allow tuning of condition monitoring to avoid false positives
– Interaction with faceplates without impact over operation
– Access to DTM only for Root Cause Analysis

May 18, 2017 Slide 83

Transform your maintenance

A scalable solution to sustain and improve the maintenance performance of a mine by accessing previously untapped asset data and
then compiling and present it efficiently.

Maintenance
AssetVista Packages
Value

Excellence
EAM Maintenance process
Integration change initiated by
analytics derived
Execution,
information
leveraging real
and near-real-
Essentials time data
Reports Dashboards
Maintenance On Demand with real time
Assessment Asset asset data Condition Monitoring
800xA System Long Term Asset Management Automation, IT & network,
Data stored, Management Plan Report instrumentation, electrical, static
secured and equipment, rotating machine,
available production equipment

Time

May 18, 2017 Slide 84

 It’s all about
maintenance!

Summary
Plant Asset Management

Optimize and sustain your maintenance performance

Avoid useless maintenance and improve time to repair

Access to ABB mining and maintenance expertise

Prevents unnecessary exposure to hazardous areas

Quick and qualified decision-making process

Solution that best fits your maintenance strategy

Operation and maintenance share the same platform

May 18, 2017 Slide 85

Enterprise Asset Management Integration
Connected Life Cycle Management

Asset Performance Management

• Connecting business processes • Connecting insight and action via

• Connecting disparate data sources advanced analytics including
via common information model modeling and simulation
• Connecting real time network
control and DCS to industrial
Common
Business
application software
Information • Connecting IoT
Model

Workforce Enterprise Asset

work orders/completions
Management Management
Plant Asset
Management

Operations

May 18, 2017 Slide 86

Enterprise Asset Management
Asset Health Center – Workforce Mgmt

ABB’s EAM application for asset-intensive industries. Support best practices out of the box
and extensible innovation in EAM business processes. Its modern user interface may be
personalized to meet specific business needs or extended and integrated through a standard
based integration platform to deliver innovation.

Asset Work
Customer Benefits
– Reduce critical asset downtime, improve safety and productivity
– Improve maintenance efficiency and effectiveness
– Improve accuracy in job scheduling and completion times
– Analyze effectiveness with complete visibility into work KPIs Materials Finance

– Optimize inventory and inventory carrying costs

– Financial accountability across the entire asset lifecycle from design to decommissioning

People Analytics

May 18, 2017 Slide 87

Enterprise Asset Management
Asset Health Center – Workforce Mgmt

Forecasting – Enables transparent and accurate workforce

planning and the balancing of work requirements
Scheduling – Get the job done properly the first time –
and with the right resources, by scheduling and sequencing work
for optimal efficiency
Dispatching – Automate the order assignment process and
proactively respond to emergency situations in real time
Mobility – From rugged notebooks to the latest tablets and
smartphones, execute work in the field with the help of the
industry’s most functional and intuitive mobile application
Work Progress Monitoring – Real-time visibility into the progress
of work so that field crews and resources can be effectively
managed
Reporting and Analytics – Real-time and historical information to
improve field operations planning and
decision making

May 18, 2017 Slide 88

Enterprise Asset Management
Performance & Condition Monitoring

ABB’s asset performance management (APM) and plant asset

management (PAM) solutions provide a plan and a path to applying
condition based maintenance strategies to your asset portfolio.
Condition-based maintenance
– Asset alert workflows – recommend and initiate action
– Normalized health and consequence for fleet priorities
– Asset condition detail visualization
– Open model interface
Asset strategy
– Risk-based maintenance
– Template-based standardization and optimization
Customer benefits
– Capture operating experience in process of continuous
improvement – Reduced preventable functional failures
Optimization & planning – Reduced maintenance cost
– Extended asset life
– Assess aggregate effects and trends – maintenance priority
– Reduced risk exposure
– Replacement prioritization
– Alignment with best practices and industry standards
– Long Range Planning
(ISO 55000, PAS 55)

May 18, 2017 Slide 89

MineOptimize – Integrated Asset Management
Covering all aspects from operations to long term planning and simulation

Expanding capabilities around advanced analytics

High
and simulation
Transforming old school preventive maintenance
Monitoring systems health and identification, analysis and
mitigation of asset failure risk Simulate
What will likely
Enabling dynamic asset maintenance regiment based on near happen?
real time asset condition monitoring

Complexity
Predict Model
What might scenarios
Achieving risk-based predictive maintenance maturity to drive happen?
better resource optimization, reliability, safety and compliance Monitor
Predictive
What is
list
happening now?
Analyze
Why did it Dashboards
happen?
Report
What Statistics
happened?
Low
Low High
Business Value

May 18, 2017 Slide 90

MineOptimize Integrated Mine Operations – MO-IMO Dispatching – MO-IMOS&D
Just-in-time optimal process management

The MineOptimize way Personnel, mobile Mine operators Mobile and fixed
and fix equipment schedule, dispatch equipment report
integrated into and track operations local conditions, task
control system in real time status and location
High degree of automation and
information access enables safety and
production as per plan
MineOptimize

The traditional way

• No information about the location and

status of mobile/fixed equipment New task plans and
Operations team Production analyses
• Cannot prioritize works plans and loading sequences
working in the and statistics can be
loading sequences are calculated and
optimum level retrieved on-line
executed

May 18, 2017 Slide 91

Integrated Mine Operations
Ultimate link between control and enterprise levels

Production
Mine Design Assets Work Force Customers Investors Finance
planning

Production plan Asset availability KPI report&visualization Status on-line

Plan, Dispatch and Activity follow-up Ore Monitor and Predict

Activity report Machine operation data Production data

Work orders
Machine position

Control system Control system Control system Control system Control system Control system Control system Control system

Material
Drilling Rig LHD/Trucks Hoits Mills Flotation Stockyard Port
Handling

May 18, 2017 Slide 92

Integrated Mine Operations
Production Scheduling & Dispatch

Software package where mine operators dispatch and track operations in real time, increasing operational transparency and enabling
decisions for best operations in real time.
Functionality:
– Visibility of all resources across the mine
– Plan continuously updated, based on truly existent resources.
– Optimal response to disturbances in real time
– ISA 95 based data store holds mine’s
past present and planned
activities
– Scheduling engine supporting
optimal decision making,
including constraint checking
mechanisms to enforce resource
availability (energy, water,
equipment and personnel availability)
Integrated Mine Operations
A cockpit to provide full visibility & enable optimization

May 18, 2017 Slide 94

Integrated Mine Operations
Dispatch/operator view

May 18, 2017 Slide 95

Minerals control and optimization applications
Applying Resource Constraints: Energy, Water, Storage Capacity

Predict accurate energy demand schedules to lower purchase costs

and avoid penalties
Manage complexity from varying energy price and power
availability by allocating energy consumption to off-peak hours and
energy production to peak hours
Same framework can be used to manage of other limiting factors
such as water and fuels

Select resources to enable production schedule at minimum cost

May 18, 2017 Slide 96

Integrated Mine Operations
Example Value Proposition for Open Pit Operations

Real Time Holistic Management of Operations

– Treat open pit mining as sequence of work orders
– Schedule work orders in real time according to availability and capacity of roads, shovels, crushers, and mobile hauling equipment
– Optimally allocate operations such as maintenance and fueling

Benefits
– Maximize production through blast cycles, haulage, crushing, ore processing and transport
– Produce to plan by reducing variability
– Improve responsiveness to unplanned activities and disturbances
– Maximize equipment utilization to maximize production and productivity with the same assets
– Track and control ore inventory for maximal flow and optimal grade
– Increase operation awareness for all personnel

May 18, 2017 Slide 97

MineOptimize Information Management – MO-IM
Make goal-oriented decisions

The MineOptimize way Automated data Report process,

Single information
collection, production, energy
platform integrated
consolidation and and maintenance
into control system
calculation KPIs
Make the right decisions based on
consolidated, consistent and transparent
information
MineOptimize

The traditional way

• Manual data collection and calculations

• Information available in segregated
Consistent
documents Targets achieved Information
distribution of
• Difficulty to identify differences among based on transparent empowering goal-
information at the
multiple sources and versions information oriented decisions
plant and corporation

May 18, 2017 Slide 98

Production Information Management
Set of tools to convert data into actionable information

To meet your production and quality objectives

To evaluate if you are on target to meet those objective
If you’re not:
– Identify the deviation
– Decide the best action to get back on target

May 18, 2017 Slide 99

Production Information Management
For performance monitoring

Process and production monitoring

– Calculations and data consolidation
– Multiple periods like shift, daily, weekly, monthly

KPI overview
– Throughput, actual vs. planned, productive time, efficiencies

May 18, 2017 Slide 100

Production Information Management
For energy monitoring

Electrical energy cost tracking:

– Individual equipment counters
– Plant sections totals
– Plant totals

Specific energy consumption calculations per

– Production unit (eg, tons)
– Product

May 18, 2017 Slide 101

Production Information Management
For downtime management

Monitor plant performance and individual equipment

– Evaluate maintenance KPIs:
– OEE (picture), availability, MTBF, efficiencies
– Root cause analysis support with:
– Flexible categorization
– Multidimensional Pareto analysis (picture)
– Chronograms (picture)
– Track low production rate periods as well as stops

May 18, 2017 Slide 102

Production Information Management
For reliability analysis

Graphical analysis charts for:

– Downtime vs frequency of occurrences to identify weak points in
reliability and risk (picture)
– Equipment reliability vs runtime to evaluate the lifetime curve
(picture)
– Early notification of pattern changes in operational variables to
detect abnormal conditions
– Average failure percentage at each hour of a day (24h histogram)

May 18, 2017 Slide 103

Production Information Management
For events and alarms monitoring

Alarms analysis to identify and reduce nuisance alarms for

continuous improvement:
– EEMUA 191 Guideline chart (picture) :
• average alarms rate per hour
• peak alarm rate per hour
– Relate process values with alarms (picture)
– Statistical alarm & event analysis on frequency, duration, etc.
(picture)

May 18, 2017 Slide 104

Summary
Production Information

Enable you to realize financial targets

Empower continuous improvement
Increase efficiency
Reduce costs
Document your performance
Supports your decision making process:
– Production and performance tracking
– Process operations monitoring and reporting
– Manufacturing Performance Indicators

May 18, 2017 Slide 105