Mining, Minerals and Metals. More Megatons. Fewer Megawatts

Transcription

1 Mining, Minerals and Metals More Megatons. Fewer Megawatts

2 Our Vision A world where we can all achieve more while using less of our common planet Who We Are? The global specialist in Energy Management Our Mission We help our customers to do the most with their Energy 2

3 Being a Global Company 3

4 Head Office Midrand Warehouse: Bartlett (Isando) Regional Offices: R-Bay, DBN, PE, CPT, BLM, Nelsp, George Johannesburg Execution Centres Projects & Services (MV ED) LV Equipment Division (LV imcc) Drives Competency Centre (VSD & Eng Drives) Professional Services (Automation Systems, MES) APC (Critical Power & Cooling) 4

5 BBBEE Status - Currently on Level 4 CIDB Rating ISO 9001 PMBOK - 7EP Rating - Certified Quality Management Engineering - Project Management Professionals (PMP) AdvantageOne - Project Life Cycle Methodology Best in Class Products Solutions Services & Projects Energy Management IEC&NEMA MV/LV Equipment Consultation Energy Efficiency Audits Engineered VSDs Critical Power & Cooling Installation Assessment Industrial Performance Intelligent MCCs Process Control Systems Retrofits Engineering Turnkey Solutions 5

6 Our Mission 6

7 7

8 because Energy is your Most Important (transformation) Process Variable Raw Material Energy Transformation Process Finished Product Waste Energy Management Platform (power & control) 8

9 Comprehensive & Integrated Mining Solutions Professional Services Manufacturing Execution System Process control Machine control Motor control Electrical distribution Power monitoring & control Security Building Management Critical power Data Centers Control Sustainability Energy Efficiency Waste Reduction People, health and safety Simple Integration Competitiveness Capex & Opex reduction Increased availability Eased innovation Interoperability and openness to third party systems Flexibility & Safety Critical points management Reliability Seamless Evolution 9

10 Complete Solution Suite for the MMM Industry Power management Process management Security management Critical Power management Building management High Density Metering Power Quality Mitigation LV/MV Electrical Distribution protection & control Intelligent power & motor control Engineered Variable Speed Drives Process Control Advanced Process Control Visualization Mining Execution System Production Energy Optimization Best Practice Engineering & Project Management Access control Video surveillance Emergency lighting Intrusion detection Fire and life safety Building Management Uninterruptible Power Supply Cooling control Rack systems Surveillance White Space Management Building Management Systems Lighting Control Outdoor Lighting Control HVAC Control Power Management Power Plant Secure Infra Smart Reliability Downtime Accidents Data integrity Data integrity 10

11 Integrated Automation & Power System Architecture UPS ERP System Historian Mine Execution System Energy Efficiency System Redundant SCADA System Servers Operator Clients Engineering Station Energy Management & Control System Ethernet PAC On-Line Particle Size Analyzer Optimization & APC PAC Process Camera Energy Monitoring & Metering Distributed and Remote IO Motor Control Centre MV Switchgear Instruments and Devices 11

12 Mining Facility & Buildings Management Comprehensive Building Management, CCTV, Access Control and Energy Management Solutions to compliment the Industrial Automation Solutions

13 Mining Facility & Buildings Management

14 Critical Power Backup Avoid any Interruption of Power Supply for Process Control Equipment, IT Infrastructure and Security Systems

15 UPS, Critical Power & Cooling High efficiency at low, medium and high load levels From 19 Rack Mount to Tower Mount to Complete Data Centre Solutions Extended range automatic voltage regulation (AVR) Pure Sine wave output Simple Serial or Ethernet Integration into SCADA Systems for Maintenance & Diagnostics Add external battery packs to scale runtime from minutes to hours

16 Power Monitoring and Protection Intelligence in all Medium Voltage Electrical Distribution equipment such as Breakers and Protection Relays provide effective Monitoring and Control of the Electrical Network

17 Electrical Distribution Systems

18 MV leader with best-in-class Solutions SCADA Distribution Management System Protection relays MV Primary cubicles Prefabricated MV/LV cubicles for secondary substation MV/LV transformers Capacitors MV cubicles Electro-Intensive Utilities HV/MV prefabricated factory-assembled and engineered substation Primary switchgear MV ring main units Circuit Breakers MV cubicles Distribution automation: Feeder automation Remote control Digital Protection relays MV ring main unit

19 Power Metering Best in Class and World Leaders in Power Metering to provide the most trusted and comprehensive solution to make the Power information available to facilitate Energy savings.

20 Energy Management Enterprise Energy Management tools to quantify the cost of energy and relate it to your everyday business

21 Energy Management Systems Enterprise Energy Manager ION Enterprise Power Meters PowerView

22 Intelligent Motor Control 70% process downtime reduction 90% fewer motor burn-outs

23 Intelligent Power & Motor Control Center Advanced Process Control Motor Control Protection Energy Management

24 Low Voltage Equipment Division Market Leader in switchgear systems & Solutions Products carry the SABS mark ISO 9001:2000 quality management listing Merseta-accredited training provider Comprehensive manufacturing capability & facilities Huge install base (>25,000 sections) Switched onto excellence

25 Engineered Variable Speed Drives Drive Solutions that bring direct impact in motor and equipment efficiency and power savings

26 Engineered Drive Solutions Medium Voltage Drives up to 10MW 2.4/3.3 / 4.16 / 6.6 kv Low Voltage Drives up to 2.4MW 400/690V drives with solution approach Package Solutions: Transformer, Drive and Motor Cooling: Air and Water Regenerative Braking Solutions Integrated harmonic mitigation (12/24/36 pulses, AFE, Filters) Compatibility with new/existing motors and Fieldbus Induction and Synchronous motor control High level of reliability: Redundancy in cooling pumps and fans, Reliable components

27 Other Drive systems Mine Winders DC and AC Frequency Drives AC Soft Starters Medium Voltage Starters Static Excitors Multi-Pump Control Anti-Sway Crane Control Rotor Control Solutions Industrial Power Electronics High-Speed DC Breakers Custom Electronic Controls Electronic Lilly Controllers ABS Brake Controllers

28 Drives Competency Centre: 2x315kW VSD Winders Shaft Sinkers Teesta (India) project 2x315kW Containerized Mine Winders R6.2M VSD, PLC, HMI, Automation Software, Sensors, TeSys U Fully integrated and Engineered Solution Sold another 2 units as standard solution Schneider Electric - Division - Name Date 28

29 Process Automation System Combined automation and energy efficiency in a common architecture

30 Process Automation System PlantStruxure Architecture & Networks Engineering Station Operating & Monitoring Controllers Distributed IO and Devices High Availability Safety Instrumented System Remote Terminal Units Historian Manufacturing Execution Sys Business System Connectivity Know more

31 Our Control System Discrete control requirements Device Integration High speed logic Multitasking controller OS Motion & machine control Stand-alone operation Scaleable architecture Distributed IO Process control requirements Hot Standby Peer to peer comms Distributed functionality Process libraries Regulatory control Advanced process control Remote IO Online changes Ruggardised More Safety Extensive communication Faulty Device Replacement Hot-swap

32 Configure the entire system Configure the SCADA Architecture CAD Integration Configure the Network architecture Configure the devices Configure the Remote I/Os Configure the PLCs To configure the PLC<>PLC communication

33 Advanced Process Control Saving potential Implement Advanced Process control to deliver 3% to 10% lower power consumption (kwh / ton) - grinding circuit Out of specs PID Control Advanced Process Control

34 Advanced Process Control Solution Embedded advanced process control functionalities Model Predictive Control (MPC) Fuzzy Control Dedicated object libraries Configured using our standard engineering tools No third-party software required

35 Energy Control FDS Interlocking of non-essential Energy Consumers during peak periods Load Shedding OFF / Reduced speed for non-essential devices Priority Scheduling and Sequencing Time-of-Use-Tariff Scheduling Multi-Pump Sequencing (Underground Water Movements, Water Makeups, Stockpile Movements, Compressor Start-ups) Implementation of Intelligent Power and Motor Control Devices Real-Time Power Consumption per Individual Device Benchmarking Alarming and Predictive Maintenance Power IL Load Shedding LS Setpoint: 30%

36 Mining Execution System Opportunities for process improvement can only be properly and fully evaluated once Data has been transformed into contextualized Information to empower effective Improvement Initiatives

37 Mining Execution Systems Mining Execution Systems deliver information that enables the optimisation of production activities from order launch to finished goods

38 Reference: Voorspoed Diamond Mine De Beers Voorspoed Mine Complete Automation System R12m Project Value PLC Panels, PLC Equipment and Engineering, SCADA System, Industrial Networks, Historian, Ampla MES System, Commissioning, Hand-over and on-going Support PS Standards 5 Months Engineering for complete system! Plant Optimized during Hot Commissioning through Ampla MES Schneider Electric - Division - Name Date 38

39 Production Energy Optimization Energy Events can be identified and the Process reasons understood to enable future preventative action.

40 Engineering and Project Management Best Practice Engineered Automation Solutions and Standard Mining Library perfectly suited to the most demanding MMM Project

41 Professional Services..a Partnership Approach How can I more easily turn this into this? Functional Specifications Wiring diagrams P&ID diagrams Other. A fully functional Automation System 41

42 Best Practice Solution Engineering Large Projects Implementation Experience in Southern Africa Deep Electrical and Automation Industry Experience & Understanding Proven Project Management & detailed Implementation Methodologies Industry Leading Standards set for Industrial Applications Full Project Life Cycle Approach Global Coverage and Growth 42

43 AdvantageOne TM Life Cycle Approach Staged approach: Engage to Optimise Captures Experience Tools, Standards, Forms, Templates Industry Best Practices Includes PMBOK knowledge areas ISO 9001 certified Quality Management System Assists with Lean & Six Sigma Improvement initiatives ISA-95 Benefits Reduce risk Sustainable results Maximise solution acceptance & business returns 43

44 Project Life Cycle Stages Discover Define Goals, Objectives, Benefits & Success Measures Identify Project Stakeholders High-Level Project Costing & Implementation Schedule Discovery Services Study Define Operation Requirements, ISA95 Equipment Models Technical Performance Measures, Maintenance &Support Systems Functional Analysis & System Specification Functional Requirement Specification Design Requirements Analysis Architecture Integration User Interface Prototype Demonstration (Thin Slice or Deep Slice) Functional Design Specification Develop Programming and Configuration Detailed Engineering Customization Training Material Test Plan & In-house Testing Audit against Specification Factory Acceptance Testing Factory Acceptance Testing Certificate Implement Logistics & Safety, Detailed Planning Equipment Installation Detailed Commissioning Plan Cold & Hot Commissioning Operator Training & Maintenance Training Site Acceptance Test Certificate O&M Training Manuals As-Built Documentation Optimise Support Contracts, Service Level Agreements, Site Audits, Additional Training Engineering Assistance & Continuous Improvement 44

45 Multiple Team Approach Sales PS Consulting PS Engineering ENGAGE DISCOVER DEFINE DESIGN DEVELOP IMPLEMENT OPTIMIZE Account Manager Business Consultant Business Consultant Part Time Business Consultant Technical Consultant Engineering Staff months Schneider Electric - Automation Division Jan 2009

46 Standards - Overview SCADA & PLC Standards SCADA Standards Project PLC Standards Project Generation Software; UAG, Excel and Templates Documentation SCADA & PLC Functional Design Specifications Device Control Modules, Equipment Modules & Sequence Functionality Operator and Maintenance Manuals Installation, Configuration and Maintenance Procedures Testing, FAT, SAT and Commission Plans & Reports 46

47 Standards - History Started development early 2000 s Used on most Projects and continuously evolved Updated to keep leading edge in Market Meets and exceeds client s requirements Use Product Enhancements to accelerate standards development Speed up engineering and sign off Maintenance enhancements Client feedback on enhancements Simplification of the standards kernel 47

48 Standards - Benefits Almost all new Projects use this standard Tested multiple times and incremental testing only required One standard to understand and Maintain Enhancements done on one standard Quotation calculations based on standards repeatable & scalable Enables confidence with Fast-track and penalty projects Minimal first principal engineering Standards proposed at enquiry phase Engineers can be changed on projects.and more 48

49 Standards Vehicle Unity Application Generator (UAG) Reduced Cost & Project Schedules System implementation cost savings. Reduced risk and improved project schedules. Improved time to market by allowing the project to go live and give return on investment sooner. Improved Quality Improved software quality. Improved maintenance. Continuous Performance Improvement Standardized design and systematic improvement. Reusable customer best practices. [ Save 20% to 35% on project schedules! ] 49

50 Standards UAG System Overview Single design environment and single database for multi Control System, HMI-Supervision based systems. Structured Project Design: Consistent use of standard Naming Conventions, Programming Style and Structure provides for a Savings in the Implementation of a Project Standardized Object Libraries: Tested and proven Captured and re-used best practices Automatic Application Generation: Project control code, graphics and database are generated automatically Automatic configuration of networks in multi device systems. Change tracking and automated documentation. Open to Third party tools: Upstream: Process design Downstream: Supervision, Archiving, Simulation 50

51 Standards - Simulation Simulation built into PLC device level In-house testing and FAT signed off with full software in simulation FAT checked against the control narrative All devices, interlocks, controls and sequences tested and signed off Only Physical IO and dynamic process timing not tested at the FAT sign off. 51

52 Standards - Conclusion Reduced system costs. Reduced risk, improved software quality, improved maintenance. Improved time to market of customer projects by allowing the project to go live and enable return on investment sooner. Systematic improvements and reusable customer best practices. 52

53 Ongoing Lifecycle Service and Support Product support Spare Parts & Repair Training Migration services my plant should operate for 20 years 53

54 Example System Architectures 54

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56 Example System Architectures 56

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59 Examples: Standards & Popup Sample 59

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61 Complete Solution Suite for the MMM Industry Power management Process management Security management Critical Power management Building management High Density Metering Power Quality Mitigation LV/MV Electrical Distribution protection & control Intelligent power & motor control Engineered Variable Speed Drives Process Control Advanced Process Control Visualization Mining Execution System Production Energy Optimization Best Practice Engineering & Project Management Access control Video surveillance Emergency lighting Intrusion detection Fire and life safety Building Management Uninterruptible Power Supply Cooling control Rack systems Surveillance White Space Management Building Management Systems Lighting Control Outdoor Lighting Control HVAC Control Power Management Power Plant Secure Infra Smart Reliability Downtime Accidents Data integrity Efficiency 61

62 Solution Provider of Choice For Mining, Minerals & Metals 62