Achieving Full Autonomy in Control

Transcription

1 Achieving Full Autonomy in Control

2 Global Operations Approx.10,000 engineering staff 2 CANADA Calgary, Alberta Halifax, Nova Scotia Mississauga, Canada Montréal, Québec Niagara Falls, Ontario Oakville, Ontario Saskatoon, Saskatchewan St. John s, Newfoundland & Labrador Sorel-Tracy, Québec Sudbury, Ontario Toronto, Ontario Vancouver, British Columbia Winnipeg, Manitoba EUROPE London, England Moscow, Russia St. Petersburg, Russia CHINA Beijing Shenyang Shanghai Amherst, New York Baltimore, Maryland Boston, Massachusetts Buffalo, New York Cleveland, Ohio Denver, Colorado Houston, Texas Millburn, New Jersey USA New York, New York Pensacola, Florida Phoenix, Arizona Pittsburgh, Pennsylvania Sacramento, California San Diego, California San Francisco, California Seattle, Washington Tampa, Florida SOUTH AMERICA Antofagasta, Chile Belo Horizonte, Brazil Lima, Peru Rio de Janeiro, Brazil Santiago, Chile São Luís, Brazil São Paulo, Brazil MIDDLE EA Abu Dhabi, UAE Al Khobar, Saudi Arabia Sohar, Oman SOUTH AFRICA Johannesburg Pretoria Cape Town AURALIA Adelaide Brisbane Gladstone Mackay Melbourne Newcastle Perth Townsville Wollongong INDIA New Delhi INDONESIA Jakarta NEW CALEDONIA Nouméa

3 3 Hatch s Business Units metals COAL INDURIAL MINERALS IRON & EEL IRON ORE LIGHT METALS MINING & MINERAL PROCESSING NON-FERROUS energy NUCLEAR OIL & GAS RENEWABLE POWER THERMAL TRANSMISSION & DIRIBUTION infrastructure INFRARUCTURE SERVICES PORTS AND MARINE TERMINALS RAIL & TRANSPORTATION SYEMS WATER >US$35 billion of projects under management

4 4 Agenda Why is Full Autonomy in control important? Barrier/Challenge to Full Autonomy in Control Overcoming these barriers using Hatch Integrated Control (HIC) approach Case Study Example: Hatch Stockyard Automation Other Hatch Case Studies using HIC approach

5 5 Why is Full Autonomy in Control Important?

6 Case Study : Stockyard Operation 6 Operation : Bulk material handling stockyard. Capital intensive and large. Equipment : Stacker and reclaimer mobile machines. These mobile machines working on common stockpiles in the stockyard. Control : Manually operated. Stockpile : Stockpile layout, size, product type according to market requirements

7 Case Study : Stockyard Operation 7 What impacts performance? Performance/throughput based on operators acting upon instructions. Variations and inconsistencies highly likely due to the human factor. Direct impact on productivity. Operational capacity and flexibility would not be at ideal levels, meaning potential lost production.

8 Traditional Automation 8 For such a facility, Traditional automation can make a difference. Automatic operation of an equipment. Less operator intervention. Higher productivity, moving machines optimally to the right spot, working the buckets at the right speed, etc. More visibility. Faster response to issues. Fewer personnel requirements Fewer mistakes

9 What are the limits of Traditional Automation 9 Limited alignment with business objectives and workflow Automation scope is limited within equipment items or plant area Limited allowance for abnormal scenarios Missed improvement opportunities Systems not structured for optimisation and expansion. Minimal flexibility. Full Autonomy can address the above and more...

10 10 Challenge/Barrier to Full Autonomy in Control Lack of Coordination Traditional automation is single equipment focused; rather than overall system and not inclusive of business processes (incomplete understanding of the client s full business and operational workflow and objectives) Missed Opportunities Traditional automation focuses mainly on normal operational scenarios; failure to seize improvement opportunities from handling and recovery from abnormal scenarios System Complexity Operational support often challenging due to low visibility and diagnostics Maintainability System complexity and skill retention due to high turn over of operational staff can impact ability to maintain

11 Overcoming Challenges/Barriers through Hatch Integrated Control 11 Lack of Coordination Embed business, operational and process knowledge into an integrated and coordinated control scheme Missed Opportunities Consider and design for abnormal condition management to reduce disruption and improve system recovery time to steady state operation System Complexity Formulate and parameterise the solution to provide a configurable system with visible diagnostics to simplify maintenance and enhancements throughout the plant lifecycle Maintainability Ensure high system availability via a thorough engineering, verification and testing process (IEEE 12207)

12 12 Case Study : Stockyard Operation How can Hatch Integrated Control improve the operation? Focus areas: Safe autonomous operation without machine collision Efficient production Maximise stockyard capacity and flexibility

13 13 Case Study : Stockyard Operation Challenges Stockyard capacity dependent on ability of mobile machines to work safely and close together Stockyard flexibility dependent on ability to define and manage the stockpile ore type, size, shape, stacking pattern, etc. Stacking performance (consistency in stockpile geometry, size) has a direct effect on reclaiming performance Variability of operational performance due to manual operation System maintainability and availability can significantly impact productivity

14 14 Case Study : Stockyard Operation How can Hatch Integrated Control improve the operation? Via the Hatch Stockyard Automation (HSA) System Embeds Stockyard Management System and Machine Protection System Operators provided high flexibility in defining and configuring stockyard parameters Advanced automation for unmanned operation. Variability minimised and capacity utilisation maximised

15 15 Case Study : Stockyard Operation How can Hatch Integrated Control improve the operation? Via the Hatch Stockyard Automation (HSA) System System engineered to provide configuration changes without modifying the core underlying software. Extensive use of generic algorithms Robust and high reliability system Workflow simplified and efficiency improved

16 QUALITY Allen-Bradley POWER RUN BAT Logix5550 RUN REM I/O Rs232 OK PROG DC INPUT O K DC INPUT O K DC OUTPUT O K QUALITY Allen-Bradley POWER RUN BAT Logix5550 RUN REM I/O Rs232 OK PROG DC INPUT O K DC INPUT O K DC OUTPUT O K QUALITY Allen-Bradley POWER RUN BAT Logix5550 RUN REM I/O Rs232 OK PROG DC INPUT O K DC INPUT O K DC OUTPUT O K 16 Hatch Stockyard Automation (HSA) System Commands/Instruction 1. Commands/Instructions to simplify workflow Stockpile location Footprint Product type Stacking pattern 2. Control characteristics to allow optimisation Repose angle Density 3. Coordination Information to improve efficiency Last stacked position Last reclaimed position Last machine Stockyard Management System Stockyard (Stockpile: Yard-Row-PileNo) HMI Stockpile Edit Stockipile Edit Stockpile Edit Stockyard Display Stockpile Archive Stockipile Data Stockpile Custody Machine-Machine, Machine Stockpile Anti-collision Commands/Instruction 1. Commands/Instructions to simplify workflow Stockpile location Footprint Product type Stacking pattern 2. Control characteristics to allow optimisation Repose angle Density 3. Coordination Information to improve efficiency Last stacked position Last reclaimed position Last machine Reclaimer PLC GPS Check-in Updates Stockpile file, Machine positins Stockyard & Mobile Machines Geometry Check-out Stockpile file, anti-collision motion permissives Operator checks out the stockpile to the reclaimer Check-out Stockpile file, anti-collision motion permissives Check-in Updates Stockpile file, Machine positins Operator checks out the stockpile to the stacker Operator checks in the stockpile Stacker PLC GPS

17 18 Hatch Collision Protection System Provide safe operation of machines through centralised monitoring of mobile machine positions and motions Improve stockyard utilisation by allowing closer machine operation use dynamic protection envelope which is a function of velocity/direction Improve system availability through the use of GPS data with machine position encoders as back up Provide clear Human Machine Interface with diagnostics to facilitate understanding of system behaviour

18 19 Hatch Stockyard Automation - Achievements Implemented at one of the world largest stockyard, achieving: Full unmanned stockyard mobile machine operation (labour reduction of approx. 4 operators per machine) Improved stockyard flexibility (stockpile layout can be easily reconfigured by operator; allowing client to adjust the stockpile size to improve reclaiming efficiency and adjust inventory location to suit market conditions) System reliability and dynamic envelope of collision protection improve the stockyard capacity through closer machines operation and less disruption due to system outages Productivity improvement through removal of variability due to manual operation and advanced control automation

19 20 Simplify Maintenance through Configuration Management Design systems to eliminate the need to modify the core software; modifications made through configuration of attributes e.g. Stockpile Management System allows operator to configure for each stockpile: Size Position Permitted Ore type (prevent contamination) Permitted Stacking Pattern and Reclaiming Pattern Collision Protection System allows the engineer to configure each machine without the need to modify collision protection algorithms: Mobile machine rail location and permitted movement area Geometrical dimension of each mobile machine Maximum deceleration rate of each mobile machine

20 21 Improving Availability By parametrising the software implementation into a set of generic algorithms and a set of configurable attributes; after initial detailed testing, future modifications can be implemented through configuration changes rather than core software changes this significantly improves system availability and lowers risk A bulk material handling supervisory control system called HPT developed by Hatch using this principle has achieved an availability better than 99.95, with average downtime of less than 1 hr p.a. over the last 10 years despite over 26 stages of expansion (through configuration changes)

21 23 Track Record of Hatch Integrated Control Approach Review of a mineral sands operation culminating in the delivery of AUD$3.3 million p.a. productivity improvement through the integrated control approach Review and implementation of an integrated control strategy to coordinate the crushing and milling areas enabling the operation to achieve its nameplate capacity. The HPT Route Control system has delivered a 6% productivity improvement and facilitated more than 20 stages of expansion of a bulk ore handling port, with system availability better than 99.96%.

22 24 Track Record of Hatch Integrated Control Approach The Hatch Reclaimer control strategy that has successfully delivered a performance improvement resulting in savings of over AUD$1.2 million p.a. for demurrage costs. Hatch Stockyard Automation (HSA) which has enabled safe and efficient unmanned operation of mobile machines within a stockyard, whilst improving overall efficiency and consistency at one of the largest coal ports in the world. The Hatch Virtual Spud (HVS) control technology which allows spudless dredge operation delivering productivity improvements of 10-20% by increasing the continuous mining area approx 9 fold and removing non-productive time due to spud walk and crabbing movements.

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