SIMINE CIS Services Maintenance and modernization for maximum availability Mining Technologies
It s clear that in today s mining business, costs have to be calculated down to the last cent. Let s talk instead about how to make the operation of your machines and plant even more reliable and efficient and how we can help you do so. You expect Maximum plant availability Increased productivity through reduced downtimes and maintenance times Reliable machine performance over the entire life cycle Fast, expert fault elimination Minimum disruption of operations due to maintenance work
The challenge: Reliable operation and maximum protection against equipment failure Minimizing risks and saving costs: maintenance as a success factor Maintenance of your machines and systems is quite a sizable cost factor. On the other hand, costs incurred due to unscheduled downtimes can significantly reduce the profitability of the entire company. It is essential to minimize risks while keeping expenditures as low as possible. There s more to it than that, though. Even equipment that functions perfectly today has to keep pace with the ongoing development of technology. Without continuous modernization measures, even the most advanced machines will eventually fall behind competitors in terms of performance. A key to success is therefore a maintenance strategy optimally matched to your company and to your processes. An optimum strategy not only comprises emergency plans for the shutdown of individual machines, but ideally it also covers the life cycle of the entire plant, with everything from rapid provision of the necessary maintenance and operating materials right up to comprehensive life-cycle management.
Our solution: The right service for every requirement In line with our Completely Integrated Solutions philosophy, SIMINE CIS Services support you with numerous technical services in every phase of operation, exactly in line with your requirements. We have a solution to fit every need, regardless of whether you simply need an efficient spare parts service or wish to develop your plant s full potential, or you want to outsource responsibility for maintenance completely. Our employees have comprehensive technical expertise and many years of experience in your industry. We have long been familiar with the high standards required by the mining industry and therefore keep an eye on cost-efficiency as well as mere plant availability. With our services you not only remain technically up-todate, but we provide ongoing assistance with your problems and help in achieving your targets. SIMINE CIS Services Rely on industry-specific standards and profit from all-important advantages: As a globally operating service provider we support the mining industry with a unique combination of industry-specific experience and mechanical and electrical engineering know-how. Together with a wide portfolio of customizable solutions, this enables us to guarantee optimum operation of our customers plants and equipment with certainty, even under difficult conditions.
We offer a number of services to support the development and implementation of your business objectives. Good reasons for SIMINE CIS Services Optimum availability and efficiency of your machines and systems Full utilization of the technical potential of your machines without capitalintensive investments Reduced costs for downtimes and other non-productive times Fast, reliable solution of problems Reduced maintenance costs and less capital tied up Improved plannability of budgets and better cost transparency Cost-optimized availability of spare parts, measuring devices and tools Completely matched solutions provide security for a modernization strategy for lasting technical reliability The functionality of your plant and equipment can be increased significantly through the use of modern automation and visualization systems
Global expertise the basis for SIMINE CIS service competence Siemens is represented globally at 250 locations in over 190 countries. More than 40 of these locations offer our Mining Services and can assist you with all service, maintenance and modernization assignments. Which service for what requirement? We d be glad to advise you on designing your own individual service package. The following pages provide you with an initial rough guide to available services. If you already have an efficient maintenance team, consider maintenance functions as core corporate processes, and only need the support of specialists in specific cases, then SIMINE CIS Operational Support is the solution of choice. Alternatively, if you re looking to develop latent improvement potential and are seeking an expert partner for outsourcing your maintenance and secondary processes, then you should talk to us about SIMINE CIS Maintenance Services
Tailored services Operational support Maintenance Plant modernization and optimization Service contracts Training Maintenance packages Modernization packages Spare parts and components Consulting and engineering Maintenance contracts Migration packages Benefit from the many years of experience of our 3,200 specialists dedicated to metals and mining services. SIMINE CIS Services portfolio at a glance SIMINE CIS our services for your plant Operational support... 8 9 Service contracts Spare parts and components Consulting and engineering Training Maintenance... 10 11 Maintenance packages Maintenance contracts Plant modernization and optimization... 12 15 Modernization packages Migration packages Metals & Mining Service and Support Centers... 16 Success story... 17 SIMINE CIS... 18 19 Completely Integrated Solutions 7
Operational support With SIMINE CIS Services, we provide optimum support for you and your maintenance team for all maintenance work. You can make use of various services that can be individually combined to meet your requirements on request or under a customer-specific service agreement. All parameters relevant for operation can be acquired and evaluated online in order to guarantee consistent availability of machines. Service contracts In case of technical faults in your plant and equipment, your maintenance team is required to solve the problem as quickly as possible. Take advantage of our service agreements to avoid or minimize downtime costs. Our service technicians and engineers have practical experience combined with in-depth technical expertise in automation and drive technology, measurement and control technology, process and production control systems and energy technology. They ensure that faults in your electrical systems are cleared quickly and reliably on site. Rapid reaction capability is guaranteed by a 24/7 service hotline for our contractual partners. It allows us to respond extremely effectively and to give you priority support. Individualized agreements relating to technical specifications, response and arrival times ensure that problems are resolved quickly and directly. The core element of our service agreements, however, is the development of effective maintenance programs and implementation of preventive maintenance measures jointly with our customers to provide reliable protection against faults and equipment failures. 8 Optionally we offer a number of variants for the remote monitoring of your systems and equipment, such as teleservice for electrotechnical components. In this way, technical problems can be identified and corrected even faster, and faults avoided from the outset. Our services comprise specifically: Development of the maintenance strategy Predictive/preventive maintenance Major overhaul On-call service and corrective maintenance Maintenance operation assistance Optimization of maintenance Monitoring of spare parts Updating of Web-based equipment documentation Assistance with software updates/ upgrades Spare parts and components Material and spare parts supply guaranteeing economical availability The supply and provision of auxiliary materials and operating materials, time-critical and nonurgent spares is an elementary component of a reliable materials supply system for your maintenance. With this service, we assure the availability of required materials and spare parts at reasonable cost for everything from inventory and process analysis to optimization of purchasing processes, as well as the ordering of materials. Repair and reproduction reducing time and cost expenditure We carry out any repairs on your behalf in our certified service centers or together with the particular manufacturers in that case often as an authorized service partner.
The product range covered comprises energy technology components (highvoltage and medium-voltage switchgear) as well as automation and drive systems or measuring instruments and test equipment. Thanks to the expertise of our employees, if needed we can also individually reproduce components that are discontinued or no longer available from suppliers. Consulting and engineering Utilizing potential for improvement maintenance business review and optimization program A maintenance process analysis is conducted in order to examine and evaluate the efficiency of maintenance management, maintenance planning and execution, optimization of maintenance processes, human resource and subcontractor management and spare parts supply. On the basis of these results, we identify latent optimization potential and define suitable measures to develop this potential in close cooperation with your employees. The basis for this is provided by a structured action and project plan, dedicated allocation of tasks and resource planning and by continuous project controlling for regular monitoring of success. Plant performance audit With the plant performance audit, we analyze the condition of our customers plants and their processes taking three aspects into particular account: Eliminating bottlenecks: We identify critical bottlenecks in the production process and develop suitable countermeasures. Feasibility studies for automation: On the basis of process parameters we examine the degree of automation in the production process as a whole in order to find possible ways of increasing yield through optimized control loops and fewer manual operations. Energy optimization: Investigation of the energy consumption of the plant as a whole and also the production process in order to boost energy efficiency and reduce consumption peaks. Our approach is based on the experience gained from major projects that we have successfully completed. On the basis of these studies the optimization potential is first defined and then developed together with our customer s specialists. Training Qualification of customers own employees is a key task. We support your specialists and offer comprehensive training courses in the areas of technology, equipment, operation, management and maintenance. In-house centers of competence are available additionally for special requirements (Simulation Training or the Metalls Academy). 9
Maintenance packages Our maintenance packages containing defined maintenance activities have been developed in response to the actual requirement in individual plant areas. Maintenance packages with a guaranteed lifecycle performance for electrical systems, drives and automation, for switchgears and motor management are available as well as ready-to-use solutions for the management of secondary processes and general overhauls. 10
Maintenance SIMINE CIS Services comprise a range of in-depth maintenance services that are geared to your specific maintenance- and production-related secondary processes. In this businessbased concept we work together with your specialists and focus on your corporate targets in the development of the best possible maintenance strategy for you. This means that you get the benefits of an individualized solution with the advantages of investing in a proven, modular standard solution, giving you a completely integrated solution. Maintenance contracts Takeover of maintenance processes working together for success If it is part of your corporate strategy to outsource secondary processes and if you consider maintenance of your plants as a secondary process, we can offer you a win-win partnership. Apart from carrying out any maintenance work that is due, e.g. proactive and preventive maintenance activities, daily maintenance work, repairs or special assignments during general overhauls, we can also undertake maintenance management on your behalf. Together with you, we define in particular the performance metrics such as plant reliability and availability as well as actual performance figures and the plant or machinery affected. These are laid down in a success-related contract. On the basis of these metrics it is possible firstly to gauge the success of the measures undertaken, secondly it provides an unambiguous means of determining our success bonus. We undertake either the maintenance of complete plant sections or individual components and systems such as conveyor system, electric motors or power supply systems entirely according to your requirements. But no matter how you decide, you can always be certain that your mechanical and electrotechnical equipment including automation systems and instrumentation is maintained perfectly and that material and spare parts management functions without problem. CMMS integration for plannable and transparent processes Computerized maintenance management systems (CMMS) exist for controlling all maintenance-related processes and ultimately so that your entire maintenance process can be made systematically more efficient. Many companies have already installed these systems but have often not integrated them fully in the particular processes. Our maintenance specialists support you both with the introduction of new stand-alone CMMS systems and also with the integration of CMMS as part of enterprise resource planning systems (ERP). 11
Modernization packages There are many good reasons for modernization. You may, for instance, want to adapt your machines and systems to current production requirements. Alternatively they may no longer be economical to operate compared with other equipment, or the legal requirements may have become stricter or else it may simply be necessary to replace old components. With our industry-specific and systemized modernization solutions we restore the systems used in your machines and equipment to state-of-the-art condition and at the same time ensure that they meet the high standards of efficiency and economy that you urgently need in the tough competitive environment. Investment in a modernization such as this generally pays off after a short time through increased productivity, improved production quality, reduced maintenance requirement or through the interaction of all three of these beneficial aspects. We have further developed modernization concepts for which there is frequent demand into standardized solutions. Faster, better, more productive modernization measures that pay off Our comprehensive range of modernization solutions for mining contains largescale complete solutions as well as the modernization of partial mechanisms in excavators and belt conveyor systems as well as for hoisting, traveling and slewing gear, bucket wheels and bucket chains. But our repertory also contains detailed solutions such as the modernization of drive systems with software applications that have been tried and tested in the mining industry. We have put together a representative selection of these modernization measures based on standard modules for you here. Apart from proven standard modules featuring extremely fast implementation and very short payback periods, we naturally also develop modernization concepts for the entire electrical engineering equipment of your plant individually tailored to your situation. This covers everything from planning and implementation to disposal of components and parts of the plant no longer needed. With our experience in plant construction and our technical background knowledge as a manufacturer of electrical engineering systems you profit from solutions that keep their promise when it comes to completion date, technology and economy. 12
Drive solutions for large-scale equipment in open-pit mining higher performance and availability The modernization solution Drive Applications for Mining and Material Handling comprises flexible and proven software modules for the close control of all common main drive systems of large-scale equipment used in open-pit mining, for example bucket wheel excavators or stackers. The object is to increase conveyor performance while at the same time improving plant availability. This is achieved by means of proven aids for equipment operators and intelligent automatic systems. In addition, control measures decrease mechanical wear and tear, thereby reducing maintenance costs. The solutions are based on modern SIMATIC drive controls and thus offer maximum protection for your investment and maximum functionality. Phased modernization of multimotor drive systems one after the other You can use this attractive phased concept which makes it easy on your modernization budget in order to integrate existing multimotor drive systems into the digital automation and drive technology landscape at low cost, and profit from all the advantages associated with this. Thanks to phased modernization it is possible to spread out the cost of modernization over several phases. Automation system and drive control can be replaced in the first phase and power section and motor in later phases. Investment in this cost-optimized solution pays off rapidly in terms of higher production quality, optimized plant performance and reduced maintenance requirement. 13
Modernization of belt conveyor systems reducing wear on belts, avoiding standstill The Speed-Controlled Conveyors software package offers modernization solutions for the direct control of speedcontrolled drive systems of belt conveyor systems, straight conveyor belts and curved belts. The technical control systems contained in them handle difficult operating conditions such as wet drive rolls, start-up under heavy load or electrical braking reliably and without causing vibration. You also benefit from a high degree of operating security and plant availability in case of failure of a drive unit thanks to the emergency operation facility. Jerk-free acceleration and deceleration without slipping and vibration also ensures that mechanisms and belts are not stressed in operation, thereby reducing costs for maintenance. Modernization of drive controls new drive for your plant With standardized modernization solutions for control systems such as TRANSIDYN B, SIMADYN C/D or MODULPAC C, Siemens offers the possibility of integrating existing drive systems into the modern automation and drive technology landscape. This concept can be used for many applications because of the availability of a choice of SIMATIC control systems and the use of proven solution modules. Apart from providing increased operating reliability and reduced maintenance costs, this flexible solution offers a lasting basis for technical process improvements and increases in performance in the future. Taking the strain off highly stressed mechanical equipment A lot of equipment used in mining is subject to particularly heavy wear and tear because of severe mechanical stressing. This includes, for example, belt conveyor systems, chain drives, crown gears or large gearboxes. This wear results in high maintenance costs and unscheduled equipment downtimes. With Gentle Mechanic Control we can offer a complete package of control measures aimed at minimizing mechanical stressing and its negative effects. These technical control systems also enhance equipment performance by avoiding oscillation and vibration. The most suitable measures for your plant are individually determined and implemented after measurements and in-depth consulting. Gentle Mechanic Control is also a tried and tested element of our modernization solutions Drive Applications for Mining and Material Handling and Speed-Controlled Conveyors. 14
Migration packages the secure way forward Our migration solutions allow you to change over smoothly from your existing automation system to marketleading systems. We ensure that your processes still intermesh like clockwork even over several equipment generations. The secure way forward: migration from AEG Modicon A350/A500 or SIMATIC S5 to SIMATIC S7 Replacement of these discontinued automation systems opens the door to the future for your plant automation. Our migration system allows you to change over smoothly from your existing automation system to the market-leading system SIMATIC S7. This not only opens up all the functional possibilities of our ultramodern automation system for you but also saves you the worry of potential problems that the discontinued system might cause. During modernization we ensure that your plant is shut down for the shortest possible time and also that you can make the greatest possible use of plant know-how accumulated in your existing system. This intelligent transfer of valuable existing plant data to your new automation system is known as migration. SIMATIC WinCC smooth changeover to the market-leading visualization system SIMATIC WinCC offers an impressive list of benefits from up-to-date user interfaces, a modern hardware and software platform and greatly enlarged functionality to an open software architecture for virtually unlimited expandability. However, replacement of your COROS system also offers tangible economic advantages in terms of reduced maintenance costs, higher plant availability and the potential for greater efficiency of processes. We lay the foundation for the most efficient possible migration with a software-aided system analysis. Our many years of experience with COROS and SIMATIC WinCC guarantee problemfree changeover even with complex configurations. After all, nobody knows COROS and SIMATIC WinCC better than Siemens. Modernization with SIMATIC PCS 7 systems SIMATIC PCS 7 is not only an efficient control system for automating your equipment but also an open-ended solution. If you ve used a SIMATIC PCS 7 system for a long time (e.g. version 4 or 5), we can help you take another step toward a secure future. By upgrading your system to the latest SIMATIC PCS 7 version you profit from a host of new functions and features and a significant increase in plant performance. SIMATIC PCS 7 brings your systems up to a uniform, easily expandable state which is still open for upgrading in the future. And thanks to our know-how, that comes with minimal downtimes and low risks. 15
Metals & Mining Service and Support Centers Customer Service level 1 Location: Regional Service technician Basic systems Regional Escalation Service level 2 Location: Central Experts Equipment know-how Metals & Mining Service and Support Centers Escalation Service level 3 Various locations Product manager Product developers Siemens Development Departments & OEM Partners With our Metals & Mining Service and Support Centers we combine regional know-how in the metals and mining industry with central expert knowledge. On this basis we support our customers with expert services for all operational functions in the areas of electrical engineering and automation technology. Apart from telephone support for operation and maintenance of your equipment we also have a pool of qualified employees for service call-outs on site at short notice. Our services: Remote access for online support (24 hours on 365 days) Support by experienced engineers and developers Audio/video tools for backup service Help desk with defined reaction times System documentation available online Software updates (patches, antivirus software, ) Logistics management for procurement of spares in an emergency Your benefits: Greater plant availability Short reaction times Support by experts as required Updated system documentation Fault and process tracking 16
Success story Maintenance at the world s fifth largest copper mine In the Los Pelambres copper mine in Chile a conveyor system about 13 kilometers (8 miles) long with eight 2.5-MW motors links an ore crushing plant with a treatment plant. The conveyor belts transport up to 8,700 metric tons of ore every hour at a speed of six meters per second. The contract for the complete maintenance of the entire conveyor system including maintenance planning and spare parts management was awarded to Siemens in 1999. After successful cooperation, this contract was extended at the customer s wish. An optical fiber network (OTN) connects all parts of the plant, and sensors detect important parameters indicating the state of all components. As a result, we are able at any time to monitor the conveyor system and its peripheral equipment outside the mine as well, and to identify potential malfunctions in advance and/or rectify them directly online in some cases. Customer: Plant type: Los Pelambres copper mine, Chile 13-km conveyor system, ore crushing plant, ore treatment plant Our solution: Maintenance of the entire conveyor system including remote maintenance via optical fiber network The result: Increased plant availability and productivity enabled operating costs to be reduced significantly. 17
Completely Integrated Solutions with SIMINE CIS Integrated offerings for increased plant performance Higher availability Measurable process improvement Greater productivity Integrated information technology Reduced life-cycle costs Maximum protection of your investment End-to-end process optimization We create the foundation for optimized processes with our engineering services and with leading automation, drive and energy supply products for all steps in the process from extraction to material logistics to final processing. At their core, these products are built on proven Siemens standards. We use this basis to set the benchmarks for efficiency and ergonomics through continual innovation and new technologies. Examples range from the world s first gearless dragline (SIMINE CIS DRAG) and our ring motors for processing plants (SIMINE CIS MILL) to completely new processes for pelletizing plants (SIMINE CIS Pellet). Further solutions round out our portfolio for everything from water and sewage needs to power supply and other infrastructure projects, including all aspects of security for your mine. Efficient process control Competitive processes also hinge on the quality of information processing. Data from various process steps must be condensed and compared against planning data to ensure an optimal process flow. Siemens solutions in the areas of IT and MES (Manufacturing Execution Systems) lead the field for the mining industry, providing full transparency from the process to the planning and management level. Patented solutions produce systematic quality assurance, efficient logistics, flexible production and schedule planning, as well as end-to-end tracking and tracing from extraction to the processed material and back such as SIMINE CIS MAQ for creating the optimal quality mix. Maximized life-cycle return Siemens services help your mine achieve high profitability throughout its entire life cycle. We start in the planning, approval and financing phases, setting the course for a rapid, on-time start-up of operations. Efficient service measures and a reliable supply chain for spare parts ensure high availability of your equipment during active operation. Last but not least, we ensure timely modernization so that your mine remains competitive while complying with strict environmental regulations. Every product in the SIMINE CIS portfolio is equipped for a smooth hardware and software migration so you benefit from current innovations while protecting the value of your investment. 18
There are three primary aspects to increasing productivity and minimizing costs in the mining industry: raising the potential in each individual process step, optimizing the entire process chain to fully exploit synergies, and ensuring competitive performance throughout the entire life cycle. Our Completely Integrated Solutions cover all these aspects. The name SIMINE CIS stands Perfect integration of every aspect for a coordinated spectrum of products, services and expertise. From engineering to the implementation of leading electrical technology, from IT solutions for optimized process control to equipment modernization SIMINE CIS is your single source for optimizing production and logistics processes. 19
For further information contact: Siemens AG Industry Sector Industry Solutions Mining Technologies Schuhstr. 60 91052 Erlangen, Germany Fax: +49 9131 7-22233 E-mail: mining@siemens.com The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order No.: E10001-M5-A16-V1-7600 Printed in Germany Dispo No.: 21662 K No.: 28400 GB C-MTMI5208M03 WS 04082. Subject to change without prior notice Siemens AG 2008. All rights reserved. SIMINE, TRANSIDYN, SIMADYN, MODULPAC, SIMATIC and COROS are trademarks of Siemens AG. CIS = Completely Integrated Solutions www.siemens.com/mining