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Slide 2 System Platform The Base For Enabling Intelligent Operations At A Gold Mine Andr Vuilleumier Managing Director Slide 3 Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary Slide 4 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. Slide 5 Following the Pattern Production lows in 2006 cause concern Production Original installation is not compatible with corporate standard and causes a safety hazard when transferring personnel between plants eg is running motor indicated as RED or GREEN? Control philosophy Fix? Replace? Upgrade? Get the Gold! Systems Anywhere required!!! Slide 6 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 Slide 7 Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary Slide 8 Spoilt for choice WIS Expert System Active Factory InTouch SCADA Historian ArchestrA Platform V3 Rockwell Allen Bradley PLC Slide 9 to S U C C E S S Requirement Specification! Network upgrade Thin Slice approved by client Upgrade 17x PLCs, integrate to ArchestrA Expert System Slide 10 Inside Specification Slide 11 Slide 12 PLC ArchestrA Interface Standard DOL Motor Inside Specification Slide 13 Slide 14 Slide 15 InTouch Smart Symbols Inside Specification Slide 16 Inside Slide 17 Slide 18 Slide 19 Slide 20 Slide 21 Slide 22 Slide 23 Slide 24 Slide 25 Its not inside its on top. The Expert System Supervisory Control System Takes over the functionality of changing the setpoints from the operator & brings the mill to peak performance Takes over the functionality of changing the setpoints from the operator & brings the mill to peak performance Three elements are involved Three elements are involved Filtering of the process variables individually through a moving average & checking them against their parametersFiltering 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/decreasedCom 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 consistentThis 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! Slide 26 Inside Expert System Filtering of the process variables individually through a moving average & checking them against their parameters Slide 27 Inside Expert System 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 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. Slide 28 Inside Expert System Slide 29 Slide 30 Slide 31 Inside Slide 32 Inside Expert System Slide 33 WIS The 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/areas that they would normally have access to Displays include KPIs Production reports Trends Published InTouch Screens. Geita can now get the right info at the right time to improve their plants performanc e Slide 34 Inside WIS Slide 35 Slide 36 Slide 37 Slide 38 Slide 39 Slide 40 Slide 41 Slide 42 Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary Slide 43 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. Slide 44 Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary Slide 45 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 24/7 911, What's Your Emergency? Slide 46 Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary Slide 47 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, & UDAs 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 Slide 48 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 its improvement as variability is decreased. Corne Lourens Metallurgical Manager, Geita Gold Mine Slide 49 Q & A A business has to be involving, it has to be fun and it has to exercise your creative instincts. Richard Branson