Anglo American Platinum Standardizes on PlantPAx Hybrid Process Solution at their Precious Metal...

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ISA88 Structured Process Solution Batch, Continuous and Hybrid Processes

Hermanus du Preez

Control Technology Specialist

November 2014


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Hermanus du Preez

Qualification : B.Eng (Process Control Engineer)

Current Position : Control Technology Specialist

15 years Automation and Control experience -> Mining & Petrochem

Responsible for ALL Regulatory and Advanced Process Control Projects

and Strategies at Anglo Platinum Precious Metal Refinery (PMR)


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Agenda

Structure, Key Features, Issues and Solutions

Anglo American Platinum Overview

Why the NEED to Upgrade?

Solution Options & Why Rockwell Automation?

Project Implementation

Project Outcome

Benefits and Realization

Conclusion


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Anglo American Platinum

World’s largest producer of primary platinum

Produces about 40% of all newly mined platinum in the

world each year.

Mining and Process (Concentrators, Smelters and

Refineries) Division

Precious Metal Refinery based in Rustenburg, South Africa

In 2012 produced 2,336,148 Platinum ounces

Products

Catalytic converters, Fuel Cells, Jewellery and various

other industrial applications


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Platinum Process Overview


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PMR Area Overview

Different PGM are processed in different Bays, consisting of several Areas, including a Tank Farm and Site Utilities

Each Area consists of several Units, with it’s respective Equipment Phases and Equipment Modules

Approximately 70 Areas, with a total 395 Units, which have similarities, but are ALL Unique

Process Area

Areas

Units

Phases

Equipment

Control Modules


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Why the NEED to Upgrade?

Specialized skills required to maintain custom sequence manager -> Ex-Support

Proprietary driver out-of-date. Could not upgrade -> EN2T does not work!

Long start-up delays (1-2 hrs) -> Entire tag database has to be loaded first

All code in Logix configure in Continuous Tasks -> No prioritization

Limited upgrade potential due to timeslice constraints.

2x Resources required to support different systems and structures

SCADA On-Line edits not possible.

SEQ

Citect

APC Custom Build Sequence Manager

C++ Based

20x L64 Rockwell Control Logix

Proprietary API Driver

Legacy System

200k Tags

~ 20000 I/O


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Solution Options - General

WANTED:

Vertical (Single Vendor) solution

Commercial Off-the-Shelf (COTS)

Vendor Support, Experience, Knowledge and Responsiveness

Cost Effective (Minimal downtime)

Rapid Development

OPTIONS CONSIDERED:

DCS Vendor

3x Costs

Difficult to RIP and REPLACE due to existing Fibre Backbone and ControlNet Infrastructure.

Strict Access Control on existing Running plant

Rockwell Automation

Existing ControlLogix installed based

PLC flexible with DCS power -> Plant PAx & Rockwell Mining Solution

Costs.


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Solution Options – Rockwell Automation

FT Batch

No need for Recipe Management ->

Limited plant recipe changes

Ideal for “Pure” Batch process. Not

an ideal fit for Continuous or Hybrid

processes

Controllogix

Process Solutions (Plant PAx)

LBSM

(Logix Batch & Sequence Manager)

Process Objects / RAMS

(Rockwell Automation Mining Solution)

System too large/complex ISA88 objects (CM, EM & EP) flexibility

Ideal for OEM solution, continues process

startup/shutdown

Well defined libraries

Matured and well supported and

documented.

Met most of the User Requirement

specifications (Out-of-the-box) and

Rockwell flexible to meet additional

requirements.

Off-the-shelf features like Ownership,

Reporting, Propagation


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Project Implementation End State System Architecture

FT Directory Server

Domain Controllers

X45 Clients

Operator Clients

Terminal Servers (2 or more) • FT View SE Clients x 25

x40 L75 - CLX

CNet

Flex Flex Flex

FT Historian Server

Managed Ethernet Switch for Control System Network (CSN) – Ctlr Communications

FT AssetCentre Server

Engineering Workstation (14)

• FT View Studio • RSLogix 5000

Redunadant Servers

x2 HMI Server

x10 Data Servers

Primary Servers x2 HMI Server x10 Data Servers

Commercial Access Network

Managed Ethernet Switch for Control System Network (CSN) – Ctlr Communications

FT Gateway Server

Lab Systems

APC Server

Legacy System

Firewall

OPC


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Project Implementation ISA88 Implementation / Structure

ControlLogix


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Project Implementation Equipment Phase Structure

Equipment Phases designed to perform single Process Function

Chemical Addition, Transfer Out, Sampling

Process Capability

Basic Control

EM’s Basic Control

CM’s

Mode Permissives Command/Status

Unit Interface

Cm

d. In

terf

ace

Equipment Interface Conceptual Grouping of Equipment Designed for process capability

Module (object)

100% Re-Usable

Customizable

Human Requests

Report/Parameters

EP_GEN

Coordination Control Sequencing of Devices


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Project Implementation Equipment Module Structure

Equipment Modules designed to Run Continuous and Perform State Specific Action

Agitate (Stop and Start Agitator Based on Level)

Equipment Grouping

Equipment Control

CM’s Basic Control

CM’s

Mode Permissives Command/Status

Unit Interface

Cm

d. In

terf

ace

Coordination Control Sequencing of Devices

Device/Equip. Interface Conceptual Grouping of Equipment

Module (object)

100% Re-Usable

Customizable

Human Requests

Report/Parameters

EM_GEN


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Unit Procedure Reactor Model

Project Implementation S88 Grouping – Reactor Example

~ 400 Unit Procedures -> Rapid development achieved by using EP and EM Libraries

F

F

F

Unit

Reactor

Reagent 3

Reagent 2

Reagent 1

FM4100

FM4110

FM4120

CV4100

CV4110

CV4120

CV4900

CV4010

M4020

DMW

To

Filler

JX4910

M4100

M4110

M4120

FT

4100

FT

4110

FT

4120

LS4010

CV4020

CV4030

TT4020

AV4020

TIC402

0

Steam

Condensate

Equipment Phase Flow Meter Addition



Equipment Phase Transfer Out

Equipment Module Agitator

Equipment Module Temperature Control

Equipment Phase Wash


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Any Questions…?

http://xkcd.com


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Scada Overview


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Project Implementation Key Features – Unit/Area Propagation

Mode Management for group of equipment

Alarm Management for group of equipment

Aggregate Status for group of equipment

Mechanism for Defining Global Interlocks & Permissives for group of equipment

By assigning a module to a group, the ability to propagate exits

Down UP


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Project Implementation Key Features – Unit/Area Propagation

Multiple Area Button Bar

• Each button (Area 1 – 5) on the button bar represents an Area

• Each button (Area 1 – 5) links to an Area Menu window.

• Selecting a button on the Area Menu will open the associated (Unit) overview screen

• The Multiple Area Button Bar and a sample Area Menu are shown in the figure below:

Ownership

• Equipment Grouping / Propagation


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Project Implementation Key Features - Interlocking

Interlocks

First-Up Indication - Standard

Last 10 Events – Additional Functionality

Individual / Maintenance Bypass Options – Additional Functionality


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Project Implementation Key Features – Batch Reports

Batch Reporting

Operator Visibility and Tracking on HMI


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Project Implementation Key Features - Routing

Complex Routing


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Project Implementation Key Features - Parameters & Reports


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Any Questions…?

http://xkcd.com


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Project Implementation Issues and Solutions

Complex Routing and Sharing of equipment.

Legacy System operators had free reign to decide which equipment should be used and by which procedure.

Not scheduling the sharing of equipment caused additional delays.

Flexible block development and Ownership property allowed

us to create a unique routing block to schedule and manage

shared equipment


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Limited downtime available (8hrs a month)

Shutdowns are scheduled Process testing limited. Hot-commissioning after field instrumentation has been tested.

Online Edits allow for Quick Changes with Change

Management Procedures in place

Brown Fields Plant (25 years old)

Not all templates developed are ‘cut’ and ‘paste’. Different areas with similar equipment are operated differently due to available field instrumentation

Require customised libraries

Code Generation


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Project Implementation Issues and Solutions – Code Generator

Rapid Development and quick modifications achieved for Equipment Phases and Equipment Modules

Equipment Modules Equipment Phases


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Defining S88 Libraries

Upgrade done in stages from area to area Different areas have different S88 philosophies which could

complicate standard library development, which only gets defined with repeatability.

Approx. 400 similar, but Unique Unit Procedures -> standardization is achieved on EP and EM level.

Repeatability and maintaining philosophies led to rapid code generation and deployment

Equipment Module vs Equipment Phase Implementation Example : Agitator


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Project Outcomes Benefits and Realization

Stricter control over batches

Realistic model/capacity of process Live reporting of delays (Operator response time, Sampling,

Availability of equipment) Active tracking / reporting of consumables / reagents

Improved fault finding at operator level -> reduced downtime

More visibility and reporting into process at operator level

95% of all changes (Maintenance, Configuration, Alarms, etc.)can be done

directly from Scada, with the exception of forcing I/O.


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Project Outcomes Benefits and Realization

Fast-Tracking Project Implementation

Team of 5 x Rockwell Engineers and 4x Anglo Platinum Engineers

Initial Area -> 6 months from design to commissioning

Second Area -> 2 x Size of Initial -> 3 months

Third Area -> 4 x Size of Initial -> 3 months

Documented Process Flow Charts


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Conclusion

ISA 88 Allowed Modular Design

Rockwell Automation’s PlantPAx and Mining Solution supported custom

S88 philosophy implemented

Generating S88 libraries initially takes longer, but ramp-up code

generation realized as soon as libraries are repeatable.

S88 Structures / Philosophies

Define the purpose / objective of S88 structures and “STICK-TO-IT”


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Questions

Name – Hermanus du Preez

Title – Control Technology Specialist

Date -- November 2014

Date post:	25-Jun-2015
Category:	Technology
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