Version 2.0 Functional Description. Integrated Mine Operations. Version 2.0 Functional Description. 3BHS En00

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1 ABB's center f excellence frminerals prcessing, cement and aluminium Integrated Mine Operatins Integrated Mine Operatins 3BHS En00 ABB Switzerland Ltd

2 Use f DANGER, WARNING, CAUTION and NOTE This publicatin includes, DANGER, WARNING, CAUTION and NOTE infrmatin where apprpriate t pint ut safety related r ther imprtant infrmatin. DANGER WARNING CAUTION NOTE Hazards which culd result in severe persnal injury r death Hazards which culd result in persnal injury Hazards which culd result in equipment r prperty damage Alert users t pertinent facts and cnditins Althugh DANGER and WARNING hazards are related t persnal injury, and CAUTION hazards are assciated with equipment r prperty damage, it shuld be understd that peratin f damaged equipment culd, under certain peratinal cnditins, result in degraded prcess perfrmance leading t persnal injury r death. Therefre, cmply fully with all DANGER, WARNING and CAUTION ntices. TRADEMARKS Advant, AdvaBuild, AdvaCmmand, AdvaInfrm, Industrial IT, 800xA are registered trademarks f ABB Industrial Systems Inc. Centrnics is a trademark f Centrnics data Cmputer Crpratin Digital, DEC, VAX, VMS and all Digital-prducts mentined in this publicatin are registered trademarks f Digital Equipment Crpratin HP and all HP prducts mentined in this publicatin are registered trademarks f Hewlett-Packard Cmpany IBM and all IBM prducts mentined in this publicatin are registered trademarks f Internatinal Business Machines Crpratin Micrsft, MS, MS-DOS, Micrsft Access, Micrsft Excel, Micrsft Wrd, Micrsft Internet Explrer are registered trademarks, and ODBC, Windws, Windws NT, Windws 2000, Windws 2003, Windws 2008, Windws 7, Windws Vista are trademarks f Micrsft Crpratin MODBUS is a registered trademark f Guld Electrnics MOTIF and OSF are trademarks f Open Sftware Fundatin Oracle, SQL*Net, SQL*Plus and SQL*Cnnect are trademarks f Oracle Crpratin Pstscript is a registered trademark f Adbe Systems Inc. SAP, NetWeaver, SAP Web Applicatin Server, SAP business Cnnectr, SAP-XI are registered trademarks f SAP AG in Germany SPSS is a registered trademark f SPSS Inc. UNIX is a registered trademark f AT&T Crpratin X Windw System is a trademark f Massachusetts Institute f Technlgy All rights t ther Trademarks reside with their respective wners. NOTICE The infrmatin in this dcument is subject t change withut ntice and shuld nt be cnstrued as a cmmitment f ABB Switzerland Ltd. ABB Switzerland Ltd assumes n respnsibility fr any errrs that may appear in this dcument. In n event shall ABB Switzerland Ltd be liable fr direct, indirect, special, incidental r cnsequential damages f any nature r kind arising frm the use f this dcument nr shall ABB Switzerland Ltd be liable fr incidental r cnsequential damages arising frm the use f any sftware r hardware described in this dcument. This dcument and parts theref must nt be reprduced r cpied withut the written permissin f ABB Switzerland Ltd, and the cntents theref must nt be imparted t a third party nr be used fr any unauthrized purpse. The sftware described in this dcument is furnished under a license and may be used, cpied, r disclsed nly in accrdance with the terms f such license. Cpyright 2015 ABB Switzerland Ltd. All rights reserved.

3 Page 3 f 23 Cntents 1 Integrated Mine Operatins Intrductin Integrated Mine Operatins Technical Summary System Cmpnents and Architecture Cmpnents and architecture ISA95 Stre Cnfiguratin Real time data entry ISA95 Server Dispatcher (main cntrl rm) screen Remte clients HMI Mbile equipment Scheduling engine Cnnectivity t real time data Cnnectivity t ERP systems Functins available t dispatchers Visualizing status f tasks Interacting with the current schedule Identifying vilatin f usage cnstraint Rescheduling example Summary Revisin Table File name: IMO _Rev 5.dc

4 Page 4 f 23 List f Figures Figure 1: Integrated Mine Operatins - Cnceptual View... 5 Figure 2: IMO system architecture... 8 Figure 3: ISA95 Stre shwing example f equipment class cnfiguratin... 9 Figure 4: ISA95 Stre Web Client shwing example f real time data maintenance10 Figure 5: ISA95 Stre Web client shwing example f peratins schedule Figure 6: ISA95 Stre Web Client shwing example f prductin rule details Figure 7: Dispatcher screen shwing example f activities by equipment and summary f electricity usage Figure 8: Remte client with example f a task list Figure 9: Remte client with example f a task s details Figure 10: Remte client with example f a prgress reprt Figure 11: Dispatcher screen shwing Equipment view Figure 12: Dispatcher screen shwing Lcatins view Figure 13: Dispatcher screen shwing Materials view Figure 14: Dispatcher screen shwing Orders view Figure 15: Dispatcher screen shwing example f sectin with electricity usage. 17 Figure 16: Recgnizing tasks status Figure 17: Dispatcher screen shwing activity icns Figure 18: Dispatcher screen shwing relatinships between tasks Figure 19: Recgnizing vilatin f a cnstraint in resurce usage Figure 20: Planned activities befre applying energy cnstraints Figure 21: Planned activities after applying energy cnstraints Figure 22: Planned rders befre rescheduling Figure 23: Planned rders after rescheduling List f Tables Table 1: IMO Technical Summary... 7 File name: IMO _Rev 5.dc

5 Page 5 f 23 1 Integrated Mine Operatins 1.1 Intrductin Mine peratins start with careful (medium t lng term) planning, that uses infrmatin abut the re bdy, the market ecnmics and the available physical and human resurces t prduce a prductin plant that maximizes stakehlder value. Once this ptimal plan stands, prductin scheduling in real time is the mst imprtant activities in the the mine managers. The manager must deliver adherence t this plan, while maximizing peratinal efficiency and keeping the csts at their minimum. Thid task requires evaluating a cmplex set f peratinal cnstraints, while adjusting t ever changing day t day, hur t hur situatins. Amng many thers, the prductin management team has t cnstantly cnsider variables such as current re bdy prperties, restrictins in equipment availability, material transprt systems, strage levels, planned maintenance activities Figure 1: Integrated Mine Operatins - Cnceptual View File name: IMO _Rev 5.dc

6 Page 6 f 23 Integrated Mine Operatins (IMO) can be applied t prcesses that can be mdelled using the ISA 95 standard. This means that ne can sensibly define the fllwing elements: prductin rders prductin recipes structured in prductin segments prductin segments defined by equipment requirements material requirements (cnsumed, cnsumable and prduced) Availablity f resurces given by the s called capability mdels Many lgistic prcesses that are relevant in mining can be represented with these elements, fr example 1.2 Integrated Mine Operatins Undergrund mine peratins Open pit mine haulage with trucks and cnveyrs Transprt and lgistic peratins related t prt and ther deliveries t custmers. IMO is a sftware package, where mine peratrs dispatch and track peratins in real time, increasing peratinal transparency and enabling decisins fr best peratins in real time. IMO ffers the fllwing functinality: real time visibility f resurces acrss the mine peratins, schedule cntinuusly updated, based n truly existent resurces. ptimal respnse t disturbances in real time scheduling engine, supprting ptimal decisin making including cnstraint checking mechanisms t enfrce resurce availability (fr example: energy, water and equipment availability) ISA 95 based data stre that hlds mine s past present and planned activities Integrated Mine Operatins als supprts cllecting, rganizing and distributing prductin and quality infrmatin thrughut a mine. The system manages data cllected frm yur prcess via different surces, and prvides fcused infrmatin presentatin thrugh functins and cmpnents needed fr mining specific activities. IMO enables the ability t peratin in clsed lp, delivering true integratin f the OT and IT levels. The details f the Integrated Mine Operatins package are described in the next sectins. File name: IMO _Rev 5.dc

7 Page 7 f Technical Summary Item Server Applicatin Client Applicatin Cnfiguratin Applicatin Specificatin Functins fr data retrieval ptimizatin mdel data presentatin Functins fr: Visualizatin f detailed schedule Visualizatin f prcess respnses Manual scheduling Exprt f schedule t ISA 95 stre Frecast f inventries Frecast f energy cnsumptin Frecast f prductin Prductin plan data entry screens Cnfiguratin f different views Functins fr: ISA95 mdel cnfiguratin Recipe nfiguratin Table 1: IMO Technical Summary File name: IMO _Rev 5.dc

8 Page 8 f 23 2 System Cmpnents and Architecture 2.1 Cmpnents and architecture The IMO system has the fllwing cmpnents: ISA95 Stre Cnfiguratin f ISA-95 mdel Cnnectivity t real time data Cnnectivity t ERP systems Dispatcher (main cntrl rm) HMI Remte clients HMI: Fixed statins Mbile equipment Scheduling engine The IMO architecture is shwn in the figure belw. Figure 2: IMO system architecture File name: IMO _Rev 5.dc

9 Page 9 f ISA95 Stre The ISA95 Stre prvides the users with the envirnment t setup the cnfiguratin and run-time cmpnents f the ISA-95 mdel fr their prcesses. Its Server part als takes care f prviding the necessary infrmatin t ther cmpnents f the IMO system like, fr example, the main dispatcher screen r the scheduler Cnfiguratin Users can cnfigure the ISA-95 classes and define instances fr: Prcess segments lading, drilling blasting, blting Equipment classes drifts, laders drilling machine Materials (cnsumables, cnsumed and prduced) electricity, water, prduct Figure 3: ISA95 Stre shwing example f equipment class cnfiguratin File name: IMO _Rev 5.dc

10 Page 10 f Real time data entry Users can maintain the ISA 95 mdel in real time and witht service interruptins using update, add and delete peratins: Prcess request (plan) Recipe Prcess respnses Status f prcess segments Prcess segment Equipment Material Figure 4: ISA95 Stre Web Client shwing example f real time data maintenance File name: IMO _Rev 5.dc

11 Page 11 f ISA95 Server The ISA95 server cmpnent takes care f string the cnfiguratin and real time data fr the Isa95 mdel, as well as ther cnnectivity functins: ISA 95 mdel Cnfiguratin, strage and archiving f cmpnents f the ISA 95 mdel Cnnectivity twards DCS, with seamless integratin fr ABB s 800xA system Mbile equipment ERP systems (cllecting rders and sending prductin results) Maintenance system (cllecting equipment availability) Interface t the schedule engine Generates ISA-95 infrmatin, including peratins respnse Receives schedule Dispatches apprved schedule t stakehlders, acting as a data server fr The Operatr HMI client The Mbile equipment HMI Figure 5: ISA95 Stre Web client shwing example f peratins schedule File name: IMO _Rev 5.dc

12 Page 12 f 23 Figure 6: ISA95 Stre Web Client shwing example f prductin rule details File name: IMO _Rev 5.dc

13 Page 13 f Dispatcher (main cntrl rm) screen The Dispatcher screen is the main system interface twards the mine dispatcher peratrs in the cntrl rm. Users can visualize the mining activities gruping them by equipment, lcatin rders r materials, and mnitr their prgress in prgress bars. At the bttm f the screen the user can shw the usage f a selected resurce, where cnstraint vilatins are displayed (als available in a separate view fr all resurces). Frm this HMI the peratr can als initiate at any time the ptimizatin fr the current schedule and situatin. Figure 7: Dispatcher screen shwing example f activities by equipment and summary f electricity usage Web services are used t btain the main infrmatin fr this screen frm the ISA95 Stre. It als exchanges data with the scheduling engine, sending required data and receiving results frm the algrithms. The infrmatin is then presented t the users in an interactive Gantt chart, where the peratrs can perfrm manual changes, like mving a task frm ne lcatin t anther. The system takes care f updating the Gantt chart view using the input frm peratin respnses, updating the usage f resurces and checking fr cnstraint vilatins, like a due date reached r t much electricity cnsumed. File name: IMO _Rev 5.dc

14 Page 14 f Remte clients HMI Special wb based screens have been designed fr cllecting infrmatin frm peratrs wrking at remte statins, either fixed r mbile. These screens present t the peratrs the current plan and current task status, using the infrmatin frm the ISA95 Stre. At any time the users can use these clients t reprt the prgress fr their selected task. Figure 8: Remte client with example f a task list Figure 9: Remte client with example f a task s details Figure 10: Remte client with example f a prgress reprt File name: IMO _Rev 5.dc

15 Page 15 f Mbile equipment Mbile statins might nt have a cnstant reliable cnnectin t the ISA95 server due t unavailability f the data netwrk. Fr these cases it is required t use special ff-line units that act as a data cllectr ndes, keeping in lcal strage any updated transactins until a recnnectin takes place. Only then the data can be sent t the main IMO system, synchrnized with ther transactins and the Dispatcher main screen can be updated accrdingly. The peratr wuld use these mbile clients t see the current plan and update the status f tasks, even when the main system is nt reachable n-line. Cntact ABB fr infrmatin n handling these cases with ABB s Fleet Manager. 2.5 Scheduling engine The scheduling engine is initiated manually frm the Dispatcher screen. It uses web services t imprt data frm the ISA95 Stre and t send results back int it. This engine will frmulate the ptimizatin prblem cnstraints and execute a selected algrithm t slve the specific lgistic prblem at hand, reprting any resulting exceptins. 2.6 Cnnectivity t real time data The fllwing systems shuld be interfaced t get real time data relevant fr scheduling the activities: Plant real time data strage levels Equipment status 2.7 Cnnectivity t ERP systems The fllwing systems shud be interfaced t get business level data relevant fr scheduling the activities: ERP and/r Mine Planning System Generates prductin plan Receives plant status Receives prductin results Maintenance system Generates maintenance plan Receives equipment status File name: IMO _Rev 5.dc

16 Page 16 f 23 3 Functins available t dispatchers The IMO system calculates the ptimal schedule cnsidering the ISA95 mdel, the real time data and any defined cnstraints. The Dispatcher screen shws the current schedule displayed in a Gantt chart with the fllwing infrmatin sectins: Equipment view Lcatins view Orders view Materials view (resurces usage) Figure 11: Dispatcher screen shwing Equipment view Figure 12: Dispatcher screen shwing Lcatins view Figure 13: Dispatcher screen shwing Materials view File name: IMO _Rev 5.dc

17 Page 17 f 23 Figure 14: Dispatcher screen shwing Orders view Figure 15: Dispatcher screen shwing example f sectin with electricity usage 3.1 Visualizing status f tasks The peratrs can easily identify the current tasks status in the main screen: A hair line with the current time (Nw) is clearly shwn A red shaded bx indicates perids f unknwn status: tasks might r might nt be cmpleted during that time The last time when an update was received is then easily recgnized Every time the peratrs reprt the prgress f tasks frm their remte statins the Dispatcher screen updates the view accrdingly. Figure 16: Recgnizing tasks status File name: IMO _Rev 5.dc

18 Page 18 f Interacting with the current schedule Users can use drag and drp peratins t: Fix tasks in time Reassign rders t different equipment Edit the capability f the different resurces Furthermre, the system prvides a large set f ptins allwing the users t custmize their user experience and the scheduling algrithms t be deplyed. Fr example: users can chse t shw activity icns fr quick identificatin, and visually mark the relatinships between tasks fr a single rder. Figure 17: Dispatcher screen shwing activity icns Figure 18: Dispatcher screen shwing relatinships between tasks File name: IMO _Rev 5.dc

19 Page 19 f Identifying vilatin f usage cnstraint When material cnstraint vilatins are identified and the peratrs are nt satisfied with the current schedule, they can initiate an ptimizatin task and the system will evaluate the situatin and prpse a better plan. Figure 19: Recgnizing vilatin f a cnstraint in resurce usage File name: IMO _Rev 5.dc

20 Page 20 f Rescheduling example In the example frm Figure 19 abve there are sme vilatins n the usage f energy. The peratr can check the different views and initiate a rescheduling frm the Dispatcher screen. The figures belw shw the plan fr the activities befre and after the system perfrms the rescheduling ptimizing the plan t satisfy the cnstraints f energy cnsumptin. Figure 20: Planned activities befre applying energy cnstraints Figure 21: Planned activities after applying energy cnstraints File name: IMO _Rev 5.dc

21 Page 21 f 23 While in the Equipment view abve it might nt be s clear t sme users the verall effect f the new plan, in the Orders view it can be quickly identified that certain rders are nw pstpned t a later perid. Figure 22: Planned rders befre rescheduling Figure 23: Planned rders after rescheduling File name: IMO _Rev 5.dc

22 Page 22 f 23 4 Summary Integrated Mine Operatins (IMO) is the ultimate decisin supprt tl fr the scheduling task. It prvides: real time visibility n the plan, shws the extent t which this plan is being fulfilled and the status f the resurces available t get there. Mrever, IMO shws nt just the past and the present situatin, but als the future f these peratins and hw different crrective actins will influence the utcmes. This ABB system enables miners t increase their peratinal agility, yield and equipment utilizatin, generating inmense value. Several prcesses relevant in mining can prfit frm using IMO as peratinal platfrm, fr example: Undergrund mine peratins Open pit mine haulage with rads, trucks, shvels, cnveyrs and crushers Transprt and lgistic peratins related t prt and ther deliveries t custmers. File name: IMO _Rev 5.dc

23 Page 23 f 23 5 Revisin Table Rev. ind. Page (P) Chapt.(C) Descriptin Date Dept. / Init.. First issue, 3BHS En00 May 2015 PAPI / EG, SCV File name: IMO _Rev 5.dc