Upload
sebastian-rowland
View
33
Download
1
Tags:
Embed Size (px)
DESCRIPTION
Khumani Mining Application. Johann Pienaar Director, Iritron (Pty) Ltd. Introduction. Project Solution. Agenda. Benefits. Considerations. Summary. ASSMANG. ASSMANG shareholders – ASSORE and ARM Iron Ore, Manganese and Chrome - PowerPoint PPT Presentation
Citation preview
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
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
IntroductionIntroductionIntroductionIntroduction
Project SolutionProject SolutionProject SolutionProject Solution
BenefitsBenefitsBenefitsBenefits
ConsiderationsConsiderationsConsiderationsConsiderations
SummarySummarySummarySummary
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
Graphic Building Blocks
Graphic Building Blocks
Link Object Attributes
Link Object Attributes
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!
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
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
IntroductionIntroductionIntroductionIntroduction
Project SolutionProject SolutionProject SolutionProject Solution
BenefitsBenefitsBenefitsBenefits
ConsiderationsConsiderationsConsiderationsConsiderations
SummarySummarySummarySummary
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
IntroductionIntroductionIntroductionIntroduction
Project SolutionProject SolutionProject SolutionProject Solution
BenefitsBenefitsBenefitsBenefits
ConsiderationsConsiderationsConsiderationsConsiderations
SummarySummarySummarySummary
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
IntroductionIntroductionIntroductionIntroduction
Project SolutionProject SolutionProject SolutionProject Solution
BenefitsBenefitsBenefitsBenefits
ConsiderationsConsiderationsConsiderationsConsiderations
SummarySummarySummarySummary
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!