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System Platform The Base For Enabling Intelligent Operations At A Gold Mine

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  1. System Platform The Base For Enabling Intelligent Operations At A Gold Mine André Vuilleumier Managing Director

  2. Introduction Project Solution Agenda Benefits Considerations Summary

  3. Who, What, Where Geita first came into prominence as the site of a German colonial gold mine. A German gold prospector discovered the mineral in the early 1900s in the hills surrounding modern-day Geita town. This and other discoveries triggered a gold rush in the surrounding area, attracting German and native prospectors alike. The colonial government established a mine to exploit 'Bismarck Reef'. Mining activities significantly declined, however, when Germany ceded control of its colonies to the British after their defeat in World War I. Geita regained it's prominence in the mid to late 1990s when the Tanzanian government opened the mineral sector to foreign investment. A number of medium to large-scale mining houses, including Ashanti and Anglo American, conducted extensive exploration activities in the surrounding areas. www.wikipedia The most significant outcome of those activities was the construction of the Geita Gold Mine, now owned by AngloGoldAshanti. The Geita Gold Mine is Tanzania's largest gold producer.

  4. Following the Pattern

  5. Add to basket…… • Apply the corporate standard • Standardise control philosophy • Better Alarming • History of production data • Real time and scheduled reporting • Expert System to improve production • Consistent Maintenance and Support

  6. Introduction Project Solution Agenda Benefits Considerations Summary

  7. Spoilt for choice WIS Expert System Active Factory InTouch SCADA Historian ArchestrA Platform V3 Rockwell Allen Bradley PLC

  8. to S U C C E S S

  9. InsideSpecification

  10. InsideSpecification

  11. Inside Specification PLC ArchestrA Interface Standard DOL Motor

  12. InsideSpecification

  13. InsideSpecification

  14. InsideSpecification InTouch Smart Symbols

  15. Inside

  16. Inside

  17. Inside

  18. Inside

  19. Inside

  20. Inside

  21. Inside

  22. Inside

  23. Inside

  24. Its not inside its on top…. • TheExpert System • Supervisory Control System • Takes over the functionality of changing the setpoints from the operator & brings the mill to peak performance • Three elements are involved • Filtering of the process variables individually through a moving average & checking them against their parameters • Com paring the result of each variable against the rules that are stored in the database, the result is analysed to determine wether the setpoint needs to be increased/decreased • This is then applied to a time interval ie how quickly it needs to react to the rule to ensure the production is kept consistent • The Expert Operator is programmed to check the average of the variables & adjust the setpoint every “x” minutes in order to maintain peak performance, in spite of an ever changing environment!

  25. InsideExpert System Filtering of the process variables individually through a moving average & checking them against their parameters

  26. InsideExpert System applying this to a time interval ie how quickly it needs to react to the rule The Expert Operator is programmed to check the average of the variables & adjust the setpoint every “x” minutes in order to maintain peak performance, in spite of an ever changing environment. comparing the result of each variable against the Rules that are stored in a database and the result is analyzed to determine wether the relevant setpoint needs to increased, decreased etc

  27. InsideExpert System

  28. InsideExpert System

  29. InsideExpert System

  30. Inside

  31. InsideExpert System

  32. WISThe Neighbourhood Watch WONDERWARE INFORMATION SERVER WIS • Large amounts of plant process data are aggregated into highly informative production reports tailored to AngloGold Ashanti corporate requirements • Integrated with existing IT infrastructure and web portals • WIS has helped connect plant personnel with other non Wonderware data sources so that they can access the entire plant record • Individual users at Geita have been assigned different views/area’s that they would normally have access to • Displays include • KPI’s • Production reports • Trends • Published InTouch Screens . Geita can now get the right info at the right time to improve their plant’s performance

  33. Inside WIS

  34. Inside WIS

  35. Inside WIS

  36. Inside WIS

  37. Inside WIS

  38. Inside WIS

  39. Inside WIS

  40. Inside WIS

  41. Introduction Project Solution Agenda Benefits Considerations Summary

  42. Show Me The Money! • CHANGEOVER • On a live plant! • Within maintenance shutdowns • Project spanned 12 months • BENEFITS • Corporate standard is in place • New Roadmap for future Projects • State of the art Control System with best support & training infrastructure • Alarming – ensuring safety and logging the triggers • Perhaps the biggest benefit has been the implementation and use of the WIS so that the right information gets into the hands of the right people, at the right time, so that they can improve plant performance, even when not on site.

  43. Introduction Project Solution Agenda Benefits Considerations Summary

  44. 911, What's Your Emergency? • The System specification that was drawn up has been proven to be a good guidance (WW Best Practice Guide, S95, WW System Platform Checklist) • Modeling, Structure & Concept must be done carefully before you start • Investigate the PLC Software for easy integration to ArchestrA(Automatic Tag Linking) • Thin slice and FAT Testing with approval • Problems experienced with ArchestrA V3 caused delays with commissioning (Backup you App regularly) • You must take into account that a new software release might come with teething problems • Important that Comprehensive Support Agreement is in place. • Wonderware SA team provided excellent support 24/7

  45. Introduction Project Solution Agenda Benefits Considerations Summary

  46. Conclusions • WONDERWARE INFO SERVER • Bringing the plant into the boardroom • ARCHESTRA • A new platform, sustainable for future developments • Security – incorporates Windows, InTouch & ArchestrA security all in one • Modeling – jump starts the project • IAS 3.0 SP2 – new user defined objects, & UDA’s and integrated graphics • Powerful field attributes – moving average, alarming etc • Alarming – no room for error, no engineering required • INTOUCH • Smart Symbols (ArchestrA graphics were not used due to teething problems) • Easy & quick to build new applications • Maintains a standard in the group • Indirect Tagging – 1 data source, facilitated via ArchestrA • Incorporated ActiveFactory trends to analogue pop ups, great feature, minimal engineering • HISTORIAN • Configured through ArchestrA, time saving • ACTIVE FACTORY • Enabled tag hierarchy • EXPERT SYSTEM • Increases productivity & facilitates an automation based result as opposed to a result based on human interface

  47. A Light At The End Of The Tunnel… • At Geita gold mine in Tanzania the loss of skills at all levels through the process plant necessitated the implementation of automated control as far as possible to reduce variability and increase control expertise.  • The Fuzzy Logic rules can and are implemented remotely from South Africa or anywhere else, saving time, transport costs and consultation costs.  The benefit of Fuzzy Logic Rules will increase in parallel with the increase in unit run time, as well as compound it’s improvement as variability is decreased.” • Corne Lourens Metallurgical Manager, Geita Gold Mine

  48. Q & A A business has to be involving, it has to be fun and it has to exercise your creative instincts. Richard Branson Thank You!