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Part of a major mine and plant network, Volcan Mining Company's oxide processing plant is located in difficult-to-access Peruvian terrain, high above sea level. That made the local support services provided by Rockwell Automation a big draw when implementing a new control system. The plant uses the PlantPAx process automation system with redundant processors, HMI servers and a historian for insight and reporting over Ethernet/IP across plant locations. This tight integration allows for better visibility and communication among controllers, which ultimately led to less downtime and increased production.
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Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Carlos Diaz - Project Manager
Control System Integration SAC (Process RcSI)
Jorge Oviedo – Automation Project Manager
Volcan Compañia Minera SAA (End user)
PlantPAx on Silver Oxides Leaching Plant
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Summary and Conclusions
PlantPAX application – Eng Review – Proposal – System Development
Silver Oxides Project – Development and Startup
Volcan Mining Company
Control System Integration SAC (RcSI)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Agenda
Project Summary and Conclusions
PlantPAX application – Eng Review – Proposal – System Development
Silver Oxides Project – Development and Startup
Volcan Mining Company
Control System Integration SAC (RcSI)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Volcan Mining Company
All operations are over
4300 mosl (14000 fosl)
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Volcan Mining Company
Production – World production ranking
Silver (metal) – Silver, Copper, Zinc, Lead (concentrate) 5th World largest producer of zinc (2th of Perú) 7th World largest producer of silver (1st of Perú) 8th World largest producer of lead (1st of Perú)
Mining Units
Yauli – Chungar – Cerro de Pasco – Alpamarca 10 Underground Mines – 7 Concentrator Plants – 1 Leaching Plant All Mining Unit are located over 4300 mosl (14,000 fosl) 352,000 hectares of concessions More than 70 years of operations
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Volcan Mining Company
Some mines are more than
1200 meters deep and
contain 23 km of tunnels
Man power
2500 direct workers 1500 indirect workers
2013 Production
279,600 TM Zinc 67,400 TM Lead 20,7 Millions Oz Silver
34 years of reserves
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Volcan Mining Company
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Final Project Statistics and Conclusions
PlantPAX application – Eng Review – Proposal – System Development
Silver Oxides Project – Development and Startup
Volcan Mining Company
Control System Integration SAC (RcSI)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Silver Oxides Project
Main Data
A green field project – 2500 mtpd – Next expansion 4000 mtpd 235 million dollar investment 13 years project lifetime
Main process
Crushing plant (Primary – Secondary – Tertiary) with close classification circuit – Washing plant (To remove fine material)
Bars and balls mill section (With close semiautomatic classification) Leaching in stirred tanks (48 hours residence time) CCD’s (counter current decantation) in three stages Merrill Crowe process – Smelter Filters plant – Cyanide destruction plant – Lime Plant
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Silver Oxides Project
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Silver Oxides Project
Control Platform Selection
Main considerations Mining market presence in Peru
Local support and many solution providers
Easy to learn and operate platform (intuitive to the end user)
Prestigious worldwide brand
Technical Considerations Redundancy required – Processors – Communications – Power Supplies –
Servers
A Scalable Platform with efficient licensing
Multiple communication protocols for Instrumentation and Vendor equipment
Managed Switches
Easy Integration with CISCO corporate Systems
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Silver Oxides Project
Control Platform Definition
Solutions and Systems Evaluated Rockwell Automation
Siemens
ABB
Invensys Foxboro
Emerson
Schneider
Other Considerations Previous experience of Vendor in Silver / Gold Leaching Plants
Previous installations in Volcan Mining Company
Trained personnel In House
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Project Development and Startup
Main challenges during commissioning and Startup
Integration of Schneider MCC’s (Ethernet ModBus TCP/IP) Integration of Instrumentation (Foundation Fieldbus) Integration of Vendor Pumps (Profibus DP) Integration of many Vendors (EtherNet/IP)
Pre-commissioning include testing
Controllers in plant Remote I/O cabinets and signals (EtherNet/IP) Remote I/O from other vendors (Profibus DP) Digital instruments (Crushing plant) Instrument Protocols
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Project Development and Startup
Issues during commissioning
Time response in MCC’s (Ethernet ModBus TCP/IP) Number of nodes in each Modbus master Percentage of load in main processors, because of integration of
many Vendors (Divide programs in two controllers) Testing redundancy in application servers Changes in Supervisory System (HMI) (Vendor integration) Integration and performance in Vendor applications Integration and monitoring of power systems data Networking integration and testing
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Agenda
Project Summary and Conclusions
PlantPAX application – Eng Review – Proposal – System Development
Silver Oxides Project – Development and Startup
Volcan Mining Company
Control System Integration SAC (RcSI)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Control System Integration S.A.C.
Peruvian company dedicated to develop industrial automation solutions
according to customer requirements in control, process, motion and
information areas, integrating RA hardware & software + engineering
services + Encompass and third parties.
More than...
14 years in local automation market 200 successful projects 20 years using RA products
RA Certified Recognized System Integrator:
Control & Process. Information (in progress) Major vertical markets: Mining, Food, Chemical
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Summary and Conclusions
PlantPAX application – Eng Review – Proposal – System Development
Silver Oxides Project – Development and Startup
Volcan Mining Company
Control System Integration SAC (RcSI)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Engineering Review
External engineering company
Buenaventura Ingenieros S.A. (Peru) SNC Lavalin (Peru office)
Engineering documents from customer
Control System Architecture Control System Technical Specification Control System Datasheets P&IDs Equipment list
Instruments and motors
I/O List Loop diagrams One-line electric diagrams
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Project Engineering Review
Key control requirements from customer
Distributed Control System Redundant Controllers and Power Supplies
Remote I/O included
Foundation Fieldbus for instrumentation Integration with vendor packages
Vendor control system must be based on Allen Bradley controllers with
EtherNet/IP communication
Integration with Motor Control Centers
Ethernet communication protocol
Redundant or Fault Tolerant communication infrastructure for all field buses
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Project Engineering Review
Key IT requirements from customer
Redundant or Fault Tolerant communication infrastructure for all field buses
All main communications will be EtherNet / IP Control System and Motor Control Centers
All switches must be layer 2 (managed) All twisted pair copper connections must be Cat6A Client/Server application software Process data historical server Web based reporting system KVM extenders for all workstations Use customer’s standard brands (if possible)
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Project Engineering Review
Standards from customer
IBM for rack servers SystemX 3650 M4
IBM for server cabinets Enterprise model
Lenovo for operation and engineering workstations Dual 24” LCD monitors – Full HD
Panduit for fiber optics (cables & accessories) Single mode 24 fibers – LC connectors
Cisco for distribution switches and routers IE-3010 model
Cat 6A for EtherNet communications
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PlantPAx Control System Proposal
Rockwell PlantPAx as DCS solution
Sized with PlantPAx Estimator (IAB) Based on redundant processors Based on PlantPAx software platform
Redundant HMI/Data Servers
Redundant Historian Servers
Web reports
Asset Management (optional)
Remote visualization (optional)
Function blocks & faceplates PlantPAx 2.0 library
Fieldbus & third-parties protocols integration
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PlantPAx Control System Proposal
Integration
EtherNet/IP for vendor packages Easy Encompass and Vendor Packages
integration
Rockwell Automation: Stratix 8000 switches for access level
EtherNet/IP to Foundation Fieldbus H1
gateway with accessories for
redundancy
Prosoft-Technology for third-party protocols:
ModbusTCP, Industrial EtherNet,
ProfibusDP
E+H for FF H1 instrumentation
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PlantPAx Control System Proposal
Others providers
Hoffman enclosures Nema 12 & 4X
Panduit fiber optic Path panels (rack & panel mount)
Patch cords & accessories
CISCO switches and routers
IBM Servers & communication cabinets
Lenovo workstations Black Box
KVM switch & extenders
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PlantPAx Control System Control Cabinets
Control Cabinets
Inside electrical rooms
Nema12 / IP55
All Allen Bradley marshaling
Terminal blocks, circuit breakers, power supplies, etc.
Network infrastructure
Access switches Fiber optic patch panel
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PlantPAx Control System Field Cabinets
Fields Cabinets
Field installation
Nema4X (stainless steel)
All Allen Bradley marshaling
Terminal blocks, circuit breakers, power supplies, etc.
Network infrastructure
Fieldbus gateways Access switches Fiber optic patch panel
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27
Control Cabinets (locally)
Device Level Ring (DLR) topology w/STP cable (fault toulerant)
Between Control Cabinets and Remote I/O
Cabinets
REP Fiber Optic SingleMode ring topology (fault toulerant)
Between Control Cabinets and Control
Room
Fiber Optic SingleMode start topology
Vendor packages have independent network
(router for interconnection)
PlantPAx Control System EtherNet Network
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28
PlantPAx Control System Control Room
IBM Servers
(5) SystemX 3650 M4
Lenovo Workstations
(4) ThinkStation S30 3 OWS + 1 EWS
Panduit fiber optic accesories
Distribution switches
Cisco IE3010 Layer 2 and 3|
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29
PlantPAx Control System Control System Architecture
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30
PlantPAx Control System HMI Supervisory Application
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PlantPAx Control System HMI - Crushing
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PlantPAx Control System HMI - Grinding
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PlantPAx Control System HMI - Cyanidation
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34
PlantPAx Control System HMI - Clarification
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35
PlantPAx Control System HMI – Reagent Dosing
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PlantPAx Control System HMI – Area Overviews
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37
PlantPAx Control System HMI – Trending
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38
PlantPAx Control System HMI – Valve Faceplate
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39
PlantPAx Control System HMI – FVNR Motor Faceplate
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40
PlantPAx Control System HMI – VFD Faceplate
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41
PlantPAx Control System HMI – Analog & PID Faceplates
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42
PlantPAx Control System HMI – System Health
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Project Development and Startup
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Project Development and Startup
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Plant Network Distribution
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Corporate Network Monitoring
24 hour x 7 days monitoring
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Agenda
Project Summary and Conclusions
PlantPAX application – Eng Review – Proposal – System Development
Silver Oxides Project – Development and Startup
Volcan Mining Company
Control System Integration SAC (RcSI)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Summary
Controllers:
3 Redundant pair of ControlLogix processor 1200 wired I/O 3000 communication I/O
EtherNet
300 EtherNet nodes 280 nodes for control
20 nodes for infrastructure
Foundation Fieldbus:
+180 instruments in 25 FF H1 redundant rings Level, Pressure, Flow, pH, ORP, density
Valve digital positioners
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Project Summary
Motor Control Centers
+250 motors in 50 MCC columns distributed in 4 electrical rooms
Vendor Packages:
+16 different providers for all type of sub systems. In example: Metso (mill & lubrication system)
Prominent (reagent dosing)
FLSmidth (filters)
Cyanco (Cianide preparation)
Tecpromin (Lime plant)
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Conclusions
The technical proposal from Rockwell Automation presented by RcSI included all that was expected as end user
We got communication with all Instrumentation, Vendor equipment and MCC’s in the plant
PlantPAx allowed us to expand the system and solve the problems in a short period of time
For the next expansion the System is ready to include more signals and MCC’s
With Rockwell Automation we got exactly what we wanted
The PreComm and Startup time was 5 weeks shorter than expected
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Questions
Carlos Diaz - Project Manager
Control System Integration SAC (Process RcSI)
Jorge Oviedo – Automation Project Manager
Volcan Compañia Minera SAA (End user)
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