memsa annual meeting st. petersburg, fl september 5, 2002 walter koellner energy & automation,...
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MEMSA Annual MeetingSt. Petersburg, FLSeptember 5, 2002
Walter Koellner
Energy & Automation, Inc.
SiRAS & MIDASRemote Diagnostics
and More
Energy & Automation, Inc.
Mining Technologies
First AccessDirect Installation: 12/2001
Boliden Sweden
Energy & Automation, Inc.
Mining Technologies
Why Remote Diagnostics?
PM aids
Advanced diagnostic programs can monitor and test not only your electrical but also your mechanical systems.
Immediate software updates
No down time, software can be downloaded and installed while the machine is operating.
Keep the factory on your machine
Remote diagnostics let the factory experts help you troubleshoot immediately. No travel time is required.
On line monitoring
Find out instantly how the machine operates. Monitor operation from the site office, the Siemens office, or any Internet connection.
Energy & Automation, Inc.
Mining Technologies
SiRAS and MIDAS
The philosophy behind SiRAS Remote Diagnostics is MIDAS…
Energy & Automation, Inc.
Mining Technologies
MIDAS
SiRAS and MIDAS
Why MIDASWhy MIDAS
Normally measured data is in raw format.
It is difficult to correlate data with real events.
Data is often incompatible with programs like Microsoft Office, etc.
Problems
OurSolution
Presents processed information in a clear, precise manner.
Custom tailored user interface extract data relevant to special groups.
Seamlessly integrates with Microsoft Office tools.
Leverages expertise from Siemens factory based development and service personnel.
Energy & Automation, Inc.
Mining Technologies
SiRAS and MIDAS
Why MIDASWhy MIDAS
Problems
e l i m i n a t e dProblems
Energy & Automation, Inc.
Mining Technologies
SiRAS and MIDAS
Data size:Data size:
For a 24 hours period, 50 Million bytes of Data are accumulated for a shovel.
This Data encompasses:
Key production DataKey production Data
Complete Machine Health DataComplete Machine Health Data
Key Operations DataKey Operations Data
Power Consumption & Line Monitoring DataPower Consumption & Line Monitoring Data
Now let’s take a look at the MIDAS Parts.
Energy & Automation, Inc.
Mining Technologies
Monitoring
MMMonitoringMonitoring
IInteraction
DDiagnostics
AAnalysis
SService
M Real time monitoring with data logging
XY or YT plots to determine machine performance
Native interface to “Accuweigh”
Energy & Automation, Inc.
Mining Technologies
Interaction
MMonitoring
IIInteractionInteraction
DDiagnostics
AAnalysis
SService
I Interact with local maintenance people during normal maintenance or troubleshooting
Energy & Automation, Inc.
Mining Technologies
Diagnostics
MMonitoring
IInteraction
DDDiagnosticsDiagnostics
AAnalysis
SService
D Connect to experts from BI or Siemens at the speed
of the Internet for diagnostics and troubleshooting
Complete toolset to support all diagnostic operations
On line software upgrades
Energy & Automation, Inc.
Mining Technologies
Analysis
MMonitoring
IInteraction
DDiagnostics
AAAnalysisAnalysis
SService
A Data correlation produces easy to use recommendation
reports
Statistical data bases predict problems before they occur thereby reducing down time
Recommendation reports include lists of required parts as well as maintenance procedures
Energy & Automation, Inc.
Mining Technologies
Service
MMonitoring
IInteraction
DDiagnostics
AAnalysis
SSServiceService
S Hourly service and cost savings service packages available
Have one custom designed for you!
Energy & Automation, Inc.
Mining Technologies
Basic SiRAS Operation - Shovel Side
Software allows to run all functions of the Shovel Maintenance PC remotely by remapping the I/O vectors (similar to “PC Anywhere”)
LocalProcessorExecutes
Diagnostics
Second Static Hard Disk w/Diagnostic Application
Programs & Diagnostic Cache
Connected via internal bus
SiBAS Control Rack
SLOT PLC S7
Remote I/O on Shovelconnected via Profibus
HMITouch screen Display
Processor
Shovel Maintenance Computer
Connected via monitor interface (serial link)
PC RACK
EthernetEthernet
Wireless Ethernet Station Ethernet card
WirelessEthernet Shovel
Access Point
Energy & Automation, Inc.
Mining Technologies
Basic SiRAS Operation - Mine Office and Internet
Ethernet
Mine Host Computerwith Internet address
Telephone
Hub
Mine Connectionto Internet
Mine Computer on LAN
The Mine Host Providesthe connection to theoutside world and is alsoavailable as a monitoringstation.
Any PC on the MineNetwork can access the
shovelDial up is alsopossible
Internet
Firewall
ISP
Ethernet
Access Point
Radio tower
Main TowerBooster
Radio tower
Main Tower(Range 20 km)
Secondary Tower - for Direct LOS, if required. - can be moved around
- can be Solar powered
Access Point
Access Point
Any PC with Internet connectioncan access the shovel
Software
Mine Wireless Ethernet Station
Wireless Ethernet Station / repeater
Shovel Wireless Ethernet Station
Energy & Automation, Inc.
Mining Technologies
How does SiRAS work ?
SiRAS Remote Diagnostics re maps the I/O vectors of the Shovel Maintenance computer to a remote computer. As a result :
All Machine Functions are available remotely. The remote operator sees the same as the local electricians.
Diagnostic software can be configured remotely, downloaded to the shovel, and activated by the local electrician. Then the remote operator can immediately analyze results.
The remote operator can communicate with the local electrician by printing messages on the screen. He can also manipulate the cursor to point out problems to the local electrician. The local electrician can ask questions using the same method.
Energy & Automation, Inc.
Mining Technologies
Internet Access
Any computer with an Internet connection
and the right password
can access the Mine Host PC
which runs the Shovel Maintenance PC remotely.
Energy & Automation, Inc.
Mining Technologies
Access Point
Radio tower
Complete Coverage of a Large Pit can be obtained by asingle tower if there is a line of sight vantage point, such asthe dispatch office.
To mine Network
Booster
Wireless Ethernet Pit Configuration I
Energy & Automation, Inc.
Mining Technologies
BridgeAccess Point
Radio tower
BridgeAccess Point
Radio tower
BridgeAccess Point
Radio tower
BridgeAccess Point
Radio tower
Complete Coverage of a Large Pit can be obtained byringing the pit with a "data bridge". In this configuration,each bridge is linked with an access point, the bridges talk toeach other, and the access points talk to the machine.
To mine Network
Wireless Ethernet Pit Configuration II
Energy & Automation, Inc.
Mining Technologies
Real Time DataGathering
Logic Data Gathering
Simoreg Exciter orDrill Drive
Diagnostic Computer
DraglineSimoverts
OtherManufacturer PLCor Discreet Logic.
Profibus
Remote Monitoring for other Mine Equipment
Energy & Automation, Inc.
Mining Technologies
Standard SiRAS Hardware Package –One Time Cost
Engineering Support Consultation with local ISP personnel to optimize configuration of radio towers, and secure
connection to the mine’s LAN, etc.
Complete turn key installations are available.
On Shovel / DraglineMaintenance computer upgrade for Remote Diagnostics including software
Shovel access point with wireless Ethernet station
Ethernet Link Wireless Ethernet repeater station for intermediate tower (requ. control power)
In Mine Office Mine office access point with wireless Ethernet station
Host computer for the mine office including software. This computer is the gateway to the shovel / dragline maintenance computer and is connected to the mine’s LAN and the Internet.
Energy & Automation, Inc.
Mining Technologies
MIDAS Service Packages – Monthly Fee
Link Checking The data link operation is checked daily via the Internet
Basic Machine Monitoring The machine is monitored daily. Any condition that might lead to failures is
flagged and the mine is notified. Summary and detail fault reports are created. Motion faults trigger trace recordings which can be viewed for further analysis. All significant control warnings (e.g. line voltage low) are summarized and
available for trend analysis. Statistics are compiled weekly / monthly and transmitted to the mine.
Software Up dates Unlimited software up dates
Standard Package
SS ServiceServiceSS ServiceService
DDDiagnosticsDiagnostics
DDDiagnosticsDiagnostics
MMMonitoringMonitoring
AAAnalysisAnalysisAAAnalysisAnalysis
Energy & Automation, Inc.
Mining Technologies
IGBT 495-BII Shovel Event Report
Aitik Mine, Boliden, Gällivare, Sweden
Reporting Period: 2002/01/05 03:12:55 to 2002/01/07 12:42:33
Report shows 10 messages, which took place in 6 events
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Energy & Automation, Inc.
Mining Technologies
IGBT 495-BII Shovel Event Report
FAULT EVENT Comprised of the Following 2 Message(s)
2002/01/07 12:42:33 SIB 352 HOIST BRAKING TOO LONG
2002/01/07 12:42:33 CDA 1149 HOIST FAULT (SEE MAINTENANCE STATION)
Trace file recorded at the time of the fault.
Energy & Automation, Inc.
Mining Technologies
IGBT 495-BII Shovel Event Report
FAULT EVENT Comprised of the Following 2 Message(s)
2002/01/07 09:28:51 SIB 221 OVERSPEED CROWD
2002/01/07 09:28:50 CDA 1150 CROWD FAULT (SEE MAINTENANCE STATION)
Trace file recorded at the time of the fault.
Energy & Automation, Inc.
Mining Technologies
Other MIDAS Service Packages
Troubleshooting Assistance/Interaction (SiRAS-II) Available on a per call / hourly basis or in multiple hour packages.
Preventive and Reliability Centered Maintenance (SiRAS-AA) Track operating hours of equipment for maintenance planning Monitor temperature / vibration signatures for preventive and reliability centered
maintenance.
Production Monitoring (SiRAS-MM) Material movement are recorded using the load weigh system. Can be programmed to cover other areas of interest, e.g. the average swing angle,
average cycle time, etc.
In addition to the Standard Package we offer:
AAAnalysisAnalysis
MMMonitoringMonitoring II
InteractionInteraction
Energy & Automation, Inc.
Mining Technologies
Booked Projects
Boliden, Sweden 495B Shovel 11/01
Disputada, Chile 495B Shovel 01/02
Peak Downs, Australia 2570 Dragline 02/02
Albian Sands, Canada 3x495B Shovel 09/02
Proposals for shovels at Lee Ranch, NM, Antamina, Chile, Coteau Properties, ND