Khumani Mining Application Johann Pienaar Director, Iritron (Pty) Ltd.

Khumani Mining Application

Johann PienaarDirector, Iritron (Pty) Ltd

Agenda

IntroductionIntroductionIntroductionIntroduction

Project SolutionProject SolutionProject SolutionProject Solution

BenefitsBenefitsBenefitsBenefits

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

ASSMANG

► ASSMANG shareholders – ASSORE and ARM

► Iron Ore, Manganese and Chrome► ASSMANG sites – Beeshoek, Khumani,

Blackrock, Cato Ridge, Dwarsrivier, Machadadorp

► ASSMANG standardised on Wonderware Software in 2000

What is ASSMANG Khumani?

HPGRHPGR

Jig Plant

Jig Plant

SampleTower

SampleTower

On-Grade W&SOn-Grade W&S

Off-Grade W&SOff-Grade W&S

ROM StockpilesROM Stockpiles

ThickenerThickener

Main Plant

Main Plant

Primary&Secondary Crushing

Primary&Secondary Crushing

Overland Conveyor

Overland Conveyor

Paste Thickener

Paste Thickener

Mine AreaMine Area

Architecture

KH-SUITEVOYAGER:Information Server

SCADA Network A

Networks and Protocols

Bruce HIPER-Ring

Bruce HIPER-Ring

Load-Out HIPER-Ring

Load-Out HIPER-Ring

Plant HIPER-Ring

Plant HIPER-Ring

• Separate IT, SCADA and PLC networks

• GB single-mode fibre backbones

• UPS and Generator backup

• Redundancy

Galaxy: Size Does Matter!

► Khumani Phase 1 (September 2008): 165 Templates 6,746 Object Instances 48,358 IO 33,636 Historised Tags

► Khumani Phase 2 (2011): 200 Templates 13,000 Object Instances 90,000 IO 65,000 Historised Tags

IO Servers

► IO Servers:▪ TopServer for ContolLogix PLCs▪ DASMBTCP for Online Analysers

► Two sets of Redundant Application Servers:▪ Dual CPUs▪ 2.0 GHz Core 2 Duo ▪ 2GB of RAM▪ CPU Utilisation:

• AOS1 – Max 24%

• AOS2 – Max 15%

Agenda






System Platform 3.0 Approach

► Naming Conventions► Modelling and Standards► Deployment Considerations► Archestra Graphics► Automatic Tag Linking► Instantiating Objects► Addressing Software Problems

Naming Conventions

► P&ID derived naming convention was used for all object instances:

<site>_<area>_<equip>_<instr>_<signal>

Example: 90_DS50_PU15_FIT01_FI

► Define Template, Attribute, Script and Graphics naming conventions

► Do Your Engineering Upfront:▪ Naming Specification▪ Functional Specification▪ Detail Design Document▪ Thin-slice Archestra templates

► Wonderware Best Practices Guideline

► Wonderware System Platform Checklist

► S95 Standards

Modelling and Standards

EnterpriseEnterpriseSiteSite

AreaAreaSub-AreaSub-Area

Process CellProcess Cell

Deployment

► “Fine Tuning and Optimisation of WW System platform”

► Utilise Archestra’s multi-threading capabilities on multi-CPU servers:▪ Multiple application engines▪ Prime number scan intervals for

scan groups

Graphics Approach

► Graphic building blocks were created in the Graphics Toolbox

► The building blocks were grouped in Toolsets

► Graphic building blocks were used to create Object Graphics

► SCADA mimics were created as Local Graphics in the Area instances

► No graphics were created in Intouch - Each Intouch page contains a single Archestra symbol

Graphics Toolbox

► Create all Graphics Symbol building blocks in the Graphics Toolbox

► Graphic Symbols grouped in Graphic Toolsets

► Adhered to best practises:▪ Used only LOCAL Custom Properties▪ Made internal properties private▪ Be aware of limited error checking

Graphics Toolbox

Use Custom Properties

Use Custom Properties

Graphic Toolsets

Graphic Toolsets Graphic

Building Block

Graphic Building Block

Object Graphics

Template Graphics

Template Graphics

Object Graphics

Graphic Building Blocks

Graphic Building Blocks

Link Object Attributes

Link Object Attributes

Mimic GraphicsArea ModelArea Model

SCADA MimicsSCADA Mimics

Area InstanceArea Instance

Automatic Tag Linking

► Automatic Tag Linking is one of the most powerful features of Archestra:▪ Standardised on tag based A-B ControlLogix

PLCs▪ Implemented standard blocks in PLC▪ Rigidly enforced our chosen tag naming

convention▪ Linked to PLC tags via scripting



Instantiating Objects

► The fastest method of creating multiple instances - use the CSV Export and Import Object functionality

► Create, then Export an example instance, copy/paste the new instances and Import

► Only keep the necessary columns

► Use Excel 2007 or later

Zapping Bugs

► We were one of the first companies to start a System Platform 3.0 project:▪ ASSMANG Cato Ridge – Started

development on Beta version (July 2007)▪ ASSMANG Khumani - Started development

on Gold version (Aug 2007)► Identified NUMEROUS bugs► Progressed through Patch 1, Patch 2,

Patch 3, SP1, numerous Hot-fixes and finally SP2!

Bugs

More Bugs

▪ Copy Paste chaos!▪ Archestra Graphics: >10min to open!▪ Managed Intouch Application: >1hr to open!▪ Duplicate ID’s

Denial!

► During the first 4-months of the project:▪ We assumed that the issues were being addressed▪ We did not realize that we were the first to

experience the problems▪ We blamed most of it on finger trouble and network

problems▪ We became very creative at finding workarounds▪ We reported nothing!

Zapping the Bugs!

► From Feb 2008 to Sept 2008:▪ We started logging ALL issues - we logged more than

39 issues▪ The severity of the issues ranged from terminal to minor

irritation▪ More than 25 Hot fixes, Patches, Service Packs and

Utilities have since been issued by Wonderware to address these problems

▪ SP1 – We were the 1st and only to install SP1▪ Support staff from Wonderware EMEA and

Wonderware SA flew out to site on numerous occasions to investigate the issues

▪ We arranged weekly WebEx teleconferences with Wonderware EMEA and Wonderware USA

Reporting Procedure

► Reporting chain: SI/Client -> Wonderware SA -> Wonderware EMEA -> Wonderware USA

► Phone Wonderware support (0861 WONDER) to determine if this is a known issue

► Send supporting e-mails to [email protected] and not to individuals

► To fast-track the problem, one has to provide Wonderware with a RECIPE to replicate the problem

mailto:[email protected]

Reporting Procedure

► Recipe:▪ An in-depth description of the problem▪ Software versions - Wonderware and Microsoft▪ Wonderware SMC log-files (.aaLGX) from the View

Node, Galaxy and AOS▪ Microsoft log-files (.evt) from the Microsoft Event

Viewer – Application, Security an System▪ Screen-captures (.jpg) illustrating the problem▪ Galaxy Backup (.cab) or Object Export (.aaPKG)

► Wonderware SA can only escalate the problem to Wonderware EMEA once they have also been able to replicate the problem

Reporting Procedure

► KEEP YOUR COOL – We are all in the same boat!► Before a Hot-fix can be issued to an SI or End-User,

a signed Hot-fix agreement has to be signed

The End Result

► After SP2:▪ Archestra Graphics: <10sec to open▪ Managed Intouch Application: <30sec to open▪ All mayor bugs have been zapped!▪ The only outstanding issues are nice-to-haves, all

of which I still want!

Agenda






Benefits

► Initial development time took longer than expected due to:▪ The bugs in the software▪ The P&ID’s were never frozen▪ The PLC developers made drastic changes

in their code until very late in the project▪ Inexperience

Benefits

► However, for phase 2 of the project, the picture is completely different:▪ Development time will be drastically

reduced▪ FAT Testing and Commission time will be

minimal▪ No scalability constraints

Agenda






Considerations

► The Galaxy Repository is a critical component. Have an off-line system available for tests and as backup

► Communicate with Wonderware – bugs don’t fix themselves!

► TRAINING, TRAINING, TRAINING! Higher skills level required for Archestra than for Intouch

► Do your Engineering upfront, BEFORE you begin with your Archestra development

Considerations

► Manage Archestra biggest strength/weakness – it’s flexibility

► Draw up a System Checklist for setting up all computers in the system

► MAKE REGULAR OFF-SITE BACKUPS

► Be aware of the risks when developing in a new version of any software

► Make use of VPN Dial-In and Microsoft Remote Desktop

Agenda






Summary

► Communication and Teamwork are critical

► All software bugs can be overcome!► We have a happy client► The Archestra system works brilliantly► We are looking forward to phase-2 of

the project!

Questions

Questions?

Khumani Mining Application Johann Pienaar Director, Iritron (Pty) Ltd.

Documents

local graphics

graphics naming conventionsdo

graphics toolboxthe

object instances48

object instances90

area instancesno graphics

assmang khumani

object graphicsscada