51
Rock Crushing in Quarry Application Hanson Cement Australia Erdinc Karatas PLC & Automation Solutions in Mining Industry
Rock Crushing in Quarry Application Hanson Cement
Australia
Erdinc Karatas
PLC & Automation Solutions in Mining Industry
© ABB Group
November 18, 2013 | Slide 2
Erdinc Karatas , PLC & Automation Sales Manager,
PLC & Automation Product Group PLC,Scada&HMI
© ABB Group
November 18, 2013 | Slide 3
Otomasyon Piramidi
PLC&Scada’nın önemi
Field Instruments:
Sensors,Valves,Actuators,Drives,
Electrification Layer:
LV,MV Panels,MCC,Transformers
Control&Scada Layer:
PLC,Scada,DCS,RTU
Data Exchange Layer:
ERP,MRP,SAP
© ABB Group
November 18, 2013 | Slide 4
Tek Elden “One ABB” Çözüm
ICE (Instrumentation-Control-Electrification)
© ABB Group
November 18, 2013 | Slide 5
AC500 AC500&Digivis
AC 700F
AC500-eCo
ABB Otomasyon Platformları
Kontrolörler ve uygulama alanları
AC500&Digivis
DCS & PLC
Hibrit
Sistemler
PLC Automation
WW R&D Centers and Production
Germany,
Ladenburg
Heidelberg,
Hornberg
PLC Automation
India,
Bangalor
e
China,
Beijing
Malaysia,
KL Support
Hub
Logistics
Business Unit Sales Offices
Germany, Menden
Central stock Europe
© ABB Group November 18, 2013 | Slide 6
R&D Centers
Tech Support & Marketing Hub
© ABB Group
November 18, 2013 | Slide 7
PLC
Automation
PLC &
Automation
Comprehensive range of
Scalable PLCs
Scada
HMI control panels
Wireless Input/Output
devices
► PLCs
AC500 AC500-eCo
► Extreme Condition & Safety PLC
AC500-XC AC500-S (Safety PLC)
►HMI Control Panels
CP600 CP400
►Wireless Input / Output devices
► Scada –Digivis
PLC&Automation Product Portfolio
© ABB Group
November 18, 2013 | Slide 8
Genel PLC Sistemleri Ek fonksiyonlar
Program Yazılımı
Donanım ve aksesuarlar
4-5 günlük eğitim
Giriş Çıkış Kapasitesi
Fo
nksiy
on
ellik
32 128 512 1000+
© ABB Group
November 18, 2013 | Slide 9
Ek fonksiyonlar
Prog.Yazılımı 4
Donanım ve aksesuarlar
4-5 günlük eğitim
Fo
nksiy
on
ellik
32 128 1000+
Prog.Yazılımı 5
Prog.Yazılımı 3
Prog.Yazılımı 2
Prog.Yazılımı 1
Ek fonksiyonlar
Ek fonksiyonlar
Ek fonksiyonlar
Ek fonksiyonlar
4-5 günlük eğitim
4-5 günlük eğitim
4-5 günlük eğitim
4-5 günlük eğitim
Giriş Çıkış Kapasitesi
512
Genel PLC Sistemleri
© ABB Group
November 18, 2013 | Slide
10
4-5 günlük eğitim
4-5 günlük eğitim
4-5 günlük eğitim
4-5 günlük eğitim
4-5 günlük eğitim
3 günlük eğitim
Tek Giriş Çıkış Ailesi
Tek PLC Platformu
Tek Programlama Yazılımı
Ücretsiz Ek fonksiyonlar Genel PLC Sistemleri & ABB
AC500 your PLC from ABB CPU range - from affordable to highest performance
Easy to install with
pluggable devices
Easy to scale for
optimized
systems
Easy to use with
comfortable
software
The platform from
ABB for Factory
Automation
© ABB Group
November 18, 2013 | Slide
12
AC500 – CPU’lar Teknik Özellikler
Çok hızlı
© ABB Group
November 18, 2013 | Slide
13
AC500 your PLC from ABB Easy to scale
AC500-eCo:
CPU with on-board I/O
AC500:
up to 30,000 I/O per
fieldbus segment
AC500 your PLC from ABB Easy to scale
AC500 CPU with I/O modules.
Mixed S500, S500-eCo, S500-S
Up to 10 S500 and / or S500-eCo
I/O modules
Up to 4 communication modules
XC: Available for eXtreme
Conditions
AC500-eCo CPU with I/O
modules. Mixed S500 and S500-
eCo
Up to 10 S500 and / or S500-
eCo I/O modules
© ABB Group
November 18, 2013 | Slide
15
AC500 PLC Platformu Uygulamalarınız için Dağıtılmış Kontrol Sistemi
AC500 PLC AC500 Haberleşme protokolleri
© ABB Group
November 18, 2013 | Slide
17
AC500 PLC Sertifikalar
cUL: USA / Canada
cTIC: Australia
GOST R: Russia
Denizcilik:
ABS: USA
BV: France
DNV: Norway
GL: Germany
LRS: Great Britain
RINA: Italy
RMRS: Russia
© ABB Group
November 18, 2013 | Slide 18
AC500 IEC 61131 level 3 dilleri destekler (IL, ST, LAD,
SFC, CF)
AC500 dahili olarak ethernet,modbus,CS31 protokollerini
destekler
AC500-eco serilerinde bile dahili web server özelliği vardır
AC500 OPC server kullandığı için SCADA
uygulamalarında marka bağımsız çalışabilir.
AC500 ile ücretsiz gelen OPC server sayesinde 3. Parti
yazılımlarla AC500 haberleşebilir.
AC500’ün fark yaratan yazılımsal özellikleri
PLC &
Automation
Comprehensive range of
Scalable PLCs
Scada
HMI control panels
Wireless Input/Output
devices
© ABB Group
November 18, 2013 | Slide 19
Tüm AC500 PLC projeleri Control Builder Plus ile
programlanabilir.
AC500 sistemi SCADA, PLC programlama ve operatör panelleri
için hep kendi ürünü olan yazılımları kullanır.
AC500 PLC’ler Microsoft SQL server ve MySQL Server’a direkt
olarak veri yazıp okuyabilirler.
Kütüphanelere sahiptir:
Proses Kütüphanesi
Solar Kütüphanesi :Anlık nem, basınç , rüzgar v.b. bilgileri
kullanarak güneşin kırılma açısına kadar hesaplayan çok
gelişmiş güneş enerjisi kütüphanemiz vardır.
Motion Kütüphanesi
AC500’ün fark yaratan yazılımsal özellikleri
PLC &
Automation
Comprehensive range of
Scalable PLCs
Scada
HMI control panels
Wireless Input/Output
devices
Kablosuz yerel haberleşme için WEB
sunucusu (WLAN)
Web sayfaları PLC içinde tutulur
PS501 programı ile oluşturulur
PC’de herhangi bir programa ihtiyaç yoktur
WEB sunucuyu:
Sayfaları internet explorer ile
görüntülemek için
Parametreleri değiştirmek için
Servisin güvenilirliği için kullanabilirsiniz.
Kolay Kullanım – Web Server Özelliği Herhangi bir yerden PLC’ye erişim
Fabrika/Saha
Ofis
ABB AC500-XC PLC Automation for eXtreme Conditions
AC500-XC Environments for use
Extreme environments
High vibration
Corrosive environments
Hot ambient temperature
High humidity
High altitude
Freezing climates
AC500-XC Which global regions are ideal for XC?
Cold, hot, humid, varying
temperature
High altitude, where water
and liquids are used etc
AC500-XC Applications - Water
Water
Treatment
Desalination
Pumping
Industrial treatment
AC500-XC Applications – Mining
Mining equipment
Excavators
Conveyors
Construction equipment
Screens
Tarmac plants
Cement plants
Pile drivers
Crushers
AC500-XC Applications - Cranes
Cranes
Tower
Ship to shore
Gantry
AC500-S Safety PLC
AC500-S Safety PLC
© ABB Group November 18, 2013 | Slide 28
AC500-S Safety PLC Protection
People Machines
Environment Investment
AC500-S Safety PLC Hardware structure
1. Commu module (CM)
2. Safety CPU (SM)
3. Standard CPU (PM)
4. Safety I/O module
5. Standard I/O module
6. Safety I/O module
1 2
3
4
5
6
© ABB Group November 18, 2013 | Slide 29
© ABB Group November 18, 2013 | Slide 30
AC500-S Software Highlights
Ladder Logic-, Function Block Diagram- and Structure Text programming in acc. to IEC 61131
Programming of loops saves memory
Trigonometric functions ( COS, SIN, TAN, ASIN, ACOS, LOG usw.)
Same look and feel for safety and non-safety programming with PS501 Control Builder Plus
PLCopen Safety-Library
Programming of customized safety libraries possible
Software Code Analysis tool (PS501-SCA) for well-structured, easy understandable code saves time and money on certification issues
IO mapping: Safety IO signals can be processed in the non safety related CPU
© ABB Group
November 18, 2013 | Slide
31
CP600 Kontrol Panelleri Mükemmel HMI , Alüminyum
© ABB Group
November 18, 2013 | Slide
32
PLC &Automation Business Her Endüstriyel Uygulamaya çözümler
Su&Atık Su
İçme suyu ve Atık Su Arıtma Tesisleri
Pompa İstasyonları , isale hatları
Demineralize tesisler , yardımcı işletmeler
Belediyeler,Müteahhitler,Otomasyon firmaları
Enerji
Hidroelektirk,Rüzgar ve Solar Enerji Tesisleri
Termik Santral ve Doğlagaz santral yardımcı işletmeler
Aktif,Reaktif güç kontrolü , Primer frek. Kontrolü vb.
Bina & Altyapı
Otel,Hastane ,AVM ,Havaalanları vb.
Bina ,Jetfan,HVAC otomasyonları
Enerji Scadası
Demiryolları &
Tuneller
Metro,Tramvay ve raylı sistemler tecrübesi
Tüm tünel otomasyon çözümleri
Metro ECS kontrol sistemi (HVAC,Jetfan,Enerji,Elektrik ,TM vb.)
Telecontrol 60870-5-104 protokolü ile Enerji Scadası
Metal,Maden &
Çimento,Beton
Maden tecrübesi , Demir Çelik otomasyon uygulamaları
Beton Santrali otomasyonları
Çimento tesisi otomasyonları
OEM
Makine Üreticileri için paket çözümler
PLC;Panel ve Sürücü entegrasyonu ,programlanması
Her çeşit makineye yönelik PLC çözümleri
© ABB Group
November 18, 2013 | Slide
33
Process Control System (Edremit) AC500 with DigiVis500 for Flotation and Mill Process
Introduction
Copper and Molybdenum Mine Flotation and Mill Process Control System
“Pro Energy” and “VINS Industry” Cooperation Project (Two ABB Partners)
Whole project is under control of PM591 CPU, 1800 I/O points
Special GGDeviceLib500 Process Control Library
AC500 is at the top of control system
AC500 communicating with lots of devices such as sub PLCs, scales,
analysers, MV switchgear devices via Modbus TCP, Profibus, Modbus RTU,
Profinet, Wireless ISM
On site I/Os are collected via Profinet remote IO units
Product
AC500 PLC Components,DigiVis500 Unlimited Signals, GGDeviceLib500
© ABB Group
November 18, 2013 | Slide
34
Process Control System Topology
Mill PLC
Profibus Network
Belt Scale Belt Scale Belt Scale MV Relay MV Relay
Modbus RTU Network
Mill PLC Thickener PLC
10 x Profinet Slave RIOs
1800 I/Os
Profinet Network
X-Ray Analyser Expert System
Modbus TCP Network
Engineering Station Operator Station
Control Network
Dam Control PLC
© ABB Group
November 18, 2013 | Slide
35
© ABB Group
November 18, 2013 |
Slide 35
Process Control System (Edremit) AC500 with DigiVis500 for Flotation and Mill Process
Application:
Mill and Flotation Process Control System
Key Requirements:
Efficent operator interaction with process objects
Accurate PID loops, interlockings and applied process scenario
Challenges:
Complete automatic process control system for process industry.
© ABB Group
November 18, 2013 | Slide
36
Process Control System (Edremit) AC500 with DigiVis500 for Flotation and Mill Process
Process Screens:
Operator interaction with process
© ABB Group
November 18, 2013 | Slide
37
AC500 Compensating Sheaves Controller for Xstrata NRS Mine Hoist in Canada
© ABB Group
November 18, 2013 | Slide
38
© ABB Group
For internal use only !
Slide 38
Hanson Cement Mining quarry rock crushing application
Introduction: Australia
End User through Systems Integrator.
Mining - Quarry
VIC, AU - 2010
Hanson cement quarry located in Bacchus Marsh. Provides aggregates for buildings, crushed rock and sand materials.
Hanson operate in over 56 quarries Australia wide.
SI to provide PLC/HMI programming with ABB assistance as well as VSD and pump commissioning. SI to build control cabinet
draft A leading aggregates and premixed concrete supplier. Hanson is one of Australia’s leading supplier of heavy building materials to the construction industry.
Product offering: PM564-ETH,1 xACQ810, 3xACS355, CP450T-ETH HMI,
FMBA-01 Modbus adapters. New Solution: Keeping constant or desired levels of sand/crushed rock in
tanks. Pumping excess into overflow tanks. Analogue bed level meters used in conjunction with PLC control.
Process improvement.
© ABB Group
November 18, 2013 | Slide 39
Erdinc Karatas , PLC & Automation Sales Manager,
ABB Automation Builder
Engineering Software
for integrated industrial automation
© ABB Group
November 18, 2013 | Slide 40
Integrated Software Suite for
machine builders and system
integrators with Drive Manager
For efficient engineering of
automation
Existing software tools and new
features integrated
One single installation medium and
common installer for trouble-free
software installation
Supporting ABB controllers, ABB
devices and 3rd party devices
© ABB Group
April 2013 | Slide 40
Automation Builder Interested in Engineering Productivity?
Automation Builder Interested in Engineering Productivity?
Easy Configuration
Machine components including
PLC
Drive
Safety
Robot
HMI
Motion
I/Os
3rd Party devices
Common object structures
Common data
Automation Builder Electrical drives integration
Easy drive integration
Ready-made PLC function
blocks
Integrated Drive Manager
Drive monitoring
Drive Manager
Program & save drive
configurations in the project
Modify and compare drive
parameters
Monitor Drives
© ABB Group
November 18, 2013 | Slide 43
Motors &
Transmissions
Advanced Services
Packages and Solutions
Common Engineering Environment
Open Connectivity and Communication
© ABB Group
April 2013 | Slide 43
Automation Builder Software Strategy in Discrete Automation and Motion
© ABB Group
November 18, 2013 | Slide 44
Automation Builder Software Strategy in Discrete Automation and Motion
Motors &
Transmissions
Advanced Services
Packages and Solutions
Common Engineering Environment
Open Connectivity and Communication
© ABB Group
April 2013 | Slide 44
© ABB Group
November 18, 2013 | Slide
45
PLC1
project B
Gateway driver: TCP/IP (standard)
PLC1
project B
PLC100
project B
project A
PLC1
project B
PLC100
project B
project A project A
Online Değişim Online ulaşım ve çoklu yükleme
© ABB Group
November 18, 2013 | Slide
46
PLC1
project B
PLC100
project B
project A
PLC1
project B
PLC100
project B
project A
PLC1
project B
project A
Gateway driver: ABB TCP/IP Level 2 AC
Online Değişim Online ulaşım ve çoklu yükleme
Solar için AC500 PLC Solar Tarlası için ideal PLC : ABB AC500
© ABB Group November 18, 2013 | Slide 47
PLC &
Automation
Comprehensive range of
Scalable PLCs
Scada
HMI control panels
Wireless Input/Output
devices
© ABB Group
November 18, 2013 | Slide
48
PLC System Integrator Organisation
19 partners Industrial Coverage-OEM & Process.
• Kayseri
Process Partner
OEM Partner
Istanbul
1-Halıcı
2- YEO
3- Kontrolmatik
4- Gençler
5- Sanpa
6- Çemsan
7- Otomotion
Ankara
1-Foks
3-Prizma
4-Proenerji
Kayseri
1-Mekosan
Gaziantep
1-Mavi Elek.
Mersin
1-PLC Müh.
Bursa
1- Halıcı
Izmir
1-Espro
2- Vins
3-Lintek
Adana
1-Alan
Otomasyon
© ABB Group
November 18, 2013 | Slide
49
PLC & MOTION Sınıfı
© ABB Group
November 18, 2013 | Slide
50
Sertifikalı Eğitimler
■ Basic Level PLC trainings (1 or 2 days)
■ AC500 System & Control Builder
■ Advanced Level PLC trainings (1-3 days)
■ Communications
■ Project design
■ Codesys PLC Editor
■ Basic Level HMI trainings
■ Basic and Advanced Level Scada
■ High Availability ( HA)
■ Basic communications (PLC- Drives ,
Modbus)
■ Advanced Communications ( profinet ,
profibus, can bus..)
Training Activities
PLC,HMI &Scada Trainings
© ABB Group
November 18, 2013 | Slide
51
