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1. 11 1 2013 5 1 CIMPLICITY SOFTWARE Cimplicity is a visualization and control package that uses a client server model It helps the user to visualize the operation and perform high level analytical applications such as optimization This creates a situation where the process engineers have fast responding control for maximum profitability An example of a SCADA overview can be seen in Figure 5 1 1 where the operator has access to necessary information In addition to this the strip at the bottom shows controls in the form of electronic push buttons Plant Discrete Overview Feature List Packaging Facilities Target Fill 13 To 19 Total Caps Total Labels STATUS Recipe in Tank Next Recipe 7 Overview cat N Fig 5 1 1 An example screen in a Cimplicity project 30 The above screen has many features These include title tabbing date time toolbar left user controls bottom indicator variables a graphical display and a physical display of how the plant looks The control items such as the start stop and main menu are created in an editor to have a specific behaviour when a mouse is clicked on the icon When using the tab section it may appear that only the mid section changes however a new screen must be designed and added for each tab The indicators and display data are extracted from an external source In this way the Cimplicity software acts as the client and is served the r
2. Engineering Internship Terry Gittos 11 1 2013 The above tables list all the PID loops that are including in the project Table 5 covers the desands section while table 6 is a list of the PIDs in the scrubbing section The type of sensor or transmitter used can be seen by the first letter in that objects technical name For example FIT6120 refers to a flow meter LIT6601 however refers to a level transmitter The same is true for pressure transmitters weight transmitters density transmitters and temperature transmitters When it comes to the output of the PID the target will commonly be a pump PU or valve FV LV or TCV In the case where the output target is another PID then this is the result of cascading 3 2 DEVICE INTERLOCKING Not all analogue sensors are used in the PID loops In most cases the sensors are use to safeguard the correct operating range for that particular system Any analogue value that goes outside its normal range should trigger an event that will return it to a normal range This is the theory behind interlocking A good example of this is when a water tank is almost full the inlet valve can be turned off to prevent any further water from entering the tank This example requires that the tank level be measured and the digital valve is electrically controlled Off On The code for this is written in the PLCs using ladder logic 3 2 1 Permissives Inhibits Process Protection or Safety Different ty
3. Engineering Internship Terry Gittos 11 1 2013 volume The modules also have a PLC assigned to manage that section of PCS The pre upgrade plant flow diagram is as follows Figure 2 2 1 1 outlines a more in depth view of the process than the previous figure A key difference is that it is how the operation stands before the upgrade commences Effectively the scrubbing has been removed Fig 2 2 1 1 A flow diagram overview of the desands section shows the movement of the ore Product ore is shown in yellow and the waste ore is displayed in red Each of the modules is identical before the upgrade The process in this section of the plant is to separate the waste from the product Graduate engineers will discover new process equipment in projects undertaken Background research was completed to help gain an understanding of the client s needs Each module contains e Feed Chute regulates the ore feed upon entry to the module e Prep Screen prevents oversized ore particles entering the classifiers e Pumps These are either direct online DOL or VSD operated Pumps assist in transporting the ore Sometimes they are used in the control philosophy of the plant 14 Engineering Internship Terry Gittos 11 1 2013 e Sump Pumps to prevent flooding in sections where the liquid level might build up in the plant Simple control design has been added to these e Cyclone Clusters used to dewater ore and sepa
4. These others relate to either the process around an object preventing a failure in the system or the object itself going outside a safe area of operation In some cases analogue sensors are used to determine whether a safe operating condition is met 3 3 SPECIAL CASES Interlocking along with PID control loops make up the largest section of the control systems in FMG Wet Front End project The client has requested that more specific functions of the PCS must exist This is the special function control of the scrubber machines 5 These extra control features protect the scrubber machines since they hold a significant portion of the project cost The scrubber is a large industrial machine that needs to have its parts frequently coated with lube to prevent any downtime The ancillary system surrounding the scrubber is quite extensive and serves this purpose Each system must be actively running while the scrubber is operational 35 Engineering Internship Terry Gittos 11 1 2013 3 3 1 1 Gearbox and Pinion Lubrication System This system consists of two lube oil heaters and a pair of lube oil pumps for each gearbox and pinion The function of the heaters must be to keep the lube oil temperature above the low point of 44 deg C and below the high point of 50 deg C It performs this operation by turning on when the low set point is reached and turning off when the high set point is reached This is called relay heater control 5 The
5. The Scrubber 1 DOLs are tested first followed by the Scrubber 1 VSDs and so on This systematic approach safeguards that all the objects will be tested The various checks performed in a FAT test can also be seen These include e Interface Checks The configuration of the object on the PLC BUS and physical address is checked Used for DOL VSD and Control Valves e Code Check The code blocks in the PLC and the cimplicity screens are checked to see if they exist Used for all objects e Mode Selection The modes will be changed in every possible dynamic and tested to guarantee it is in the selected mode e interlocks The interlocks will be forced on then cleared one by one and the appropriate outcome is tested For example a safety interlock should disable the motor when active For a permissive however the motor is allowed to start but an alarm is shown SCADA should also show the corresponding change on the interlock screen Used for all objects e Drive Controls The drives are tested again while triggering interlocks Engineering Internship Terry Gittos 11 1 2013 e Auto Control Tests the analogue value written as an output voltage Used for control valves Other tests incorporate the sequences such as start up shutdown of the plant sections and special case control This testing was designed and written by senior engineer Jason Tan It shows great insight into how this system will operate and the r
6. Devices which calls all the 7 Ego devices blocks individually Another advantage from this type of block base orientation is that the code of one motor will be very similar to the code of another motor Where this is the case the function block and therefore the ladder logic can be duplicated and I O changed This means that for all similar objects a comprehensive amount of time can be saved 4 4 TESTING een Called Blocks T AAA Devices T Comms Main LD Diags Applications Comms Devices TF AAA_Devices een Caled Bioeks AG261 Cfg ml AG261 LD Calculations BK CF237 LD S CF235 LD T cisf Co T ClsfAutoClean Gorr cfg St Green LD St DIT6604 LD dl DIT6606 LD St DIT6608 LD St DIT6636 LD dl DIT6663 LD St DIT6731 LD St FCv6706 LD T FIT Co Hi FIT6603 LD Factory Acceptance Testing FAT began on the 20 of July and was completed on the 4 of September This is code only testing that ensures both the PLC code and SCADA run as expected before sending it to site Given that each object has at least two function blocks of ladder logic and two screens in Cimplicity the time for this task was significant and went well beyond the projected time as discussed in the progress report A document must be created that can be ticked off as the test is completed Both the client and Motherwell must retain a completed copy Test templates have already been created in previous projects that explain ho
7. a locked charge When the scrubber is inched forward the ore material is shaken apart preventing it from clumping The scrubber will be inched forward for a fifteen minute interval The timer values and interlock are then reset and the scrubber will assume the locked charge is broken If the charge is not broken it should be detected again on the normal start up 37 Engineering Internship Terry Gittos 11 1 2013 4 PLC System The PLCs used in this PCS are the RX3i This is a newer module GE controller that should be capable to handle the tasks we require Programming for the project was specified to be written using ladder logic The structure however was specific and unlike that taught in ENG305 PLC Systems This is largely due to the differences between the Siemens and GE software Experience with ladder logic aided the student contribution to this section of the project 4 1 PLC SOFTWARE The software used to program the PLCs is Proficy Machine Edition This is GE IP Intelligent Products software that allows the user to create powerful control and automation applications The function most used in this project is the logic developer PLC The package comes with more than just a logic developer however the building of a HMI was not required by the machine edition software as another software package was used for this When opening the machine edition software the various section of the screen have different windows to allo
8. constantly rolls down the curve side of the scrubber When a locked charge is present the normal operation is prevented due to the fact the ore does not roll down the side and scratch the outer shell Instead the ore may fall as a huge lump at one time and cause catastrophic damage to the machine For this reason it is very important to prevent a locked charge Detecting a locked charge is the first stage of preventing one This can be done one of three ways The scrubber is fitted with a position sensor and two limit switches on the outer rim Upon start up the scrubber will pass two limit switches that are 70 degrees apart It will then be stopped and the position will be recorded at that point If the scrubber settles at a point greater than 10 degrees away from the original point which should happen if something heavy is stuck on one side then it will be said to have a locked charge It will also be considered to have a locked charge when the position is less than 10 degrees but the scrubber fails to start within ten minutes of that measurement Lastly the scrubber is assumed to have a locked charge if it has been resting with slurry for longer than thirty minutes The locked charge triggers a protection interlock When a locked charge is detected it must be broken in order to resume operation The scrubber has been fitted with an inching drive for this reason The main drive will be rested and the inching drive will be activated in the case of
9. next required function for this section is called duty standby control 5 This means that one of the pumps will be the main pump duty pump to use and the other pump will be a backup that turns on only when the primary pump has failed If the secondary pump has also failed then it will switch over to the primary pump provided the issue has been resolved The primary pump can be chosen 3 3 1 2 Main Bearing Lube System This area involves two lube conditioning pumps three bearing lube main pumps four lube oil heaters and a pair of accumulator release solenoid valves This system will also contain a relay heater control for the same set points as the previous section as well as duty standby control for the first three pumps and the last two pumps In addition to this the system will also contains accumulator valve control This opens the valve every hour If the flow rate out of the valve is less that a high set point then not enough oil has accumulated and a permissive interlock is triggered If the flow rate is greater than this set point then the permissive interlock is reset 3 3 1 3 Ring Gear Grease Spray System The ring gear is a circular gearing that winds around the diameter of the scrubber This gearing which is connected to a pinion and coupled with a gearbox gives the scrubber its rotary motion Periodically three solenoid valves and a metering switch will release a metered amount of grease onto the ring gear This operation when
10. strain gauge I O the RTD I O the Thermocouple I O the Resistive I O and the Power Transducer 2 3 2 Profibus Profibus is an established communications protocol for field bus applications It is used to perform a cyclic data exchange through the master slave relationship The PLC is the master in this case Profibus PA and Profibus DP were both used for the project The difference being that Profibus PA is considered safer used exclusively in hazardous areas and runs at a speed of 31 5 Kbit s where as Profibus DP runs at a speed up to 12000 Kbit s depending on length Both use the same communications protocol and can be connected in the same network using a DP to PA connector 23 2 3 3 DeviceNet DeviceNet is an open field network that easily connects to field devices This network has less wiring and as a result has less maintenance costs The setback of DeviceNet is that it must be connected to DeviceNet devices The performance of the network is determined by the length and thickness of the cable 15 Figure 2 3 3 1 displays the capabilities of DeviceNet in accordance to its properties It stands to reason that a longer cable should be run at a slower baud rate to accommodate errors over this distance since 7 Engineering Internship Terry Gittos 11 1 2013 there will be a higher chance of errors from induction The current will also influence this and is Cable type Baud rate Max Branch Total Current accounted for in
11. to recognise that this is not an accurate representation of the amount of devices attached to these PLCs but simply gives an indication of the network and communications type Using more than one type of communications protocol was necessary to achieve the client s desired requirements Engineering Internship Terry Gittos 11 1 2013 7 Documentation Each stage of a project this large has associated documents detailing the works at that stage FMG Wet Front End includes documents that are to be delivered to the client as proof of work done Documents add structure and method to engineering work They also clarify how the sections of work were divided up For this project Motherwell constructed four key documents that are to be delivered to the client upon completion These are the detailed design FAT document SAT document and the final product document 7 1 DETAILED DESIGN SPECIFICATION The first deliverable document is the detailed design Similar to the way the project was divided into two sections so was this document In fact all the major documents were divided into a desands document and a wet scrubbing document The client hired AMC consulting engineers to test how close all the design specifications were followed from the documents FMG delivered 2 5 7 The detailed design must be completed before any PLC or SCADA programming It outlines all interlocks and controls to be programmed as well as modifications and u
12. to the team at Motherwell Automation This work environment was fantastic for developing engineering skills in my field of study Special thanks go to Paul Jones for the supportive role as industry supervisor Similarly thank you to the project team members Jason Tan Mauricio Valdez Sholeh Pirmorady Daniel Newton Ben Ratcliffe and Project Manager George Immink greatly appreciated the opportunity to work with such skilled engineers To my friends and colleagues at Murdoch University offer thanks The teams have been a part of over the years have changed me for the better Engineering Internship Terry Gittos 11 1 2013 II Executive Summary During the final stages of a bachelor of engineering at Murdoch University students are required to undertake a thesis or internship Thisis a final assessment that ensures the student can draw from their past material to produce a large project or experiment This will in turn prepare the student for a work placement in the industry This report is a final document for an engineering internship at Motherwell Automation that started in semester two of 2012 The internship project titled FMG Wet Front End involves the upgrade to an iron ore processing facility in the Pilbara region of north Western Australia The upgrade was a project acquired by Motherwell which included the installation of several new section that required electrical and automation systems For this upgrade a large section
13. 1 54 Gland water valves for the new water services area Control Valves 6751 6754 and 6755 Raw water control valves and the recycle water control valve In reference to Figure 2 2 1 1 Figure 2 4 1 4 is constructed to clarify the differences in the process facility after the upgrade Some features remain the same and yet many areas are different and it is recommended to compare the following Figure to Figure 2 2 1 1 to gain a greater understanding of the upgrade overall 24 Engineering Internship Terry Gittos 11 1 2013 Fig 2 4 1 4 Desands overview as a wet process The ore product is once again in light green Process water is in blue and waste ore is in red Figure 2 4 1 4 is the resulting flow diagram of the expansion It is colour coded as shown in Table 2 to show which PLC controls each section There are some elements missing from this illustration as it should serve as a guide to the function of the desands process PLC Colour 4262 Green 4263 Purple 4302 Light Orange 4303 Dark Orange Table 2 The table reinforces that in figure 2 4 1 4 the colours of each process block shows which PLC effectively controls the electrical system in that block The overall process is more complex but has a higher volume and quality output This serves to improve the overall efficiency and make this project a worthwhile investment 2 4 3 Wet Scrubbing Area Wet Scrubbing is a completely new se
14. 11 1 2013 AAR d Au a qo Fig 2 3 6 1 Wall mounted CEP7 The three pins at the top are connected to the field component We iB They are very DEA Si large pins due RS PRA P PS to the very large currents that will be running through them The underside in connected to the computer end lower voltage and current 13 This device is coupled with the DNY42R which acts as a distributed starter for the DOL drive The DNY42R connects the signal from the PLC over the DeviceNet to the CEP7 14 2 3 7 Samson 3730 The Samson 3730 is the control valve type used to control different systems in the project It is an electro pneumatic positioned meaning that it responds to a 4 20mA signal and moves accordingly using compressed air This is the most common device used as the PID output It is industrial sized to handle large flow rates and dense material such as the ore slurry in this project 2 3 8 Analogue Sensors Analogue sensors are the heart of a PCS For we cannot control what we cannot measure 6 2 3 8 1 SS200 Density Gauge The SS200 contains three major components to determine the density These are the source housing containing radiation source the detector and the control unit with keypad and screen interface The density is reported as specific gravity ratio of slurry density to the density of water and percentage of solids 2 3 8 2 ABB Temperature Transmitter The ABB temperature transmi
15. 40 Input Module 120VAC 16 Paints C200MDL240 Input Module 240VAC16 Points C200MDL241 Input Module 120VAC Isolated 16 Points C200MDL243 Input Module 240VAC Isolated amp Points C200MDL244 Input Module 125VDC Positive Negative Logic Isolated amp Paints C200MDLES1 a faa Pad Input Module 125VDC Positive Negative Logic Isolated 16 Points C200MDLE3 Input Module 48VDC Positive Negative Logic Grouped 16 Points C200MDLES5S Input Module 48V0C Positive Negative Logic Grouped 32 Points C200MDLES6 Input Module 24 VDC Positive Negaiive Logic 16 Points C200MDLE40 Input Module 512400 PositveiNegative Logic Grouped 16 Pointe C200MDLE43 Input Module SADC PositvvelNegative Logic Grouped 32 Paint C200MDLE4 Input Module 24VDC Positive Negative Logic 32 Points C200MDLE50 Discrete Quiput Modules Output Module 120VAC 0 5 Amp Isolated 8 Pointe C200MDLSz2 Ouiput Module 120VAC 0 5 Amp Isolated 16 Points C200MDL330 Ouiput Module 120VAC 2 0 Amp Isolated 5 Points C200MDL331 Output Module 24V0C Positive Logic 2 0 Amps wiESCP amp Paints C200MBLT30 Output Module 12 24V0C Positive Logic 0 5 Amp 16 Points C200MDLT40 Ouiout Module 24VDC Positive Logic 0 5 Amp wESCP 16 Points C200MDLT41 Output Module 244 00 Positive Logic 0 5 Amp wESGP 32 Points C200MDLT42 Ouiput Module 52 4V OC Negative Logic 0 5 Amp 16 Ponte C200MDBLT43 Ouiput Module 5 2 44VDC Negative Logic 0 5 Amp 32 Points C200MDLFA4 Duiput Module 12 24VDG Positive Logic 0 5
16. Amp 32 Pomis C200MDLT SO Output Module Relay 2 0 Ampt lsolsted Form A 9 Poinis C200MDLa30 Duiput Module Relay 2 0 Amp lsolated Form A 16 Powis C200MDLS40 Engineering Internship Terry Gittos 11 1 2013 Discrete Mixed O Modules Mixed Module 24VDC Positive Logic Input 20 Points Output Relay 2 0 Amp 12 Points C200MDD840 Mixed Module 22VDC Positive Logic Input 20 Points Output 12 Point 4 High Speed IC200MDD841 Counter PWM or Pulse Train Configurable Points Mixed Module Output 24VDC Pos Logic 0 54 Grouped wESCP 16 Points Input 24VDC C200MDD842 Pos Neg Logic Grouped 16 Points Mixed Module 24VDC Positive Logic Input Grouped 10 Points Output Relay 2 0A per Point IC200MDD843 Grouped 6 Points Mixed Module Output 12 24VDC Pos Logic 0 54 16 Points Input 24 VDC Pos Neg Logic IC200MDD844 Grouped 16 Points Mixed Module Output Relay 2 0A Isolated Points Input 24VDC Pos Neg Logic Grouped IC200MDD845 16 Points Mixed Module Output Relay 2 0A per Pt Isolated 8 Points Input 120VAC Grouped Points IC200MDD846 Mixed Module Outout Relay 2 0A per Pt Isolated 8 Points Input 240VAC Grouped Points IC200MDD847 Mixed Module Output 120VAC 0 54 per Pt Isolated 8 Points Input 120VAC Grouped 8 IC200MDD848 Points Mixed Module Output Relay 2 0A per Pt Isolated 8 Points input 120VAC Isolated 8 Points IC200MDD849 IC200ALG262 IC200ALG321 IC200ALG327 IC200AL 6328 IC200ALG331 Analog Mixed Module 12 B
17. Interlocks Protection interlocks lie on the higher end of the anti failing system Any running object with a protection interlock triggered will be stopped and alarms shown in the SCADA The object will also not be able to be started until the issue is resolved These interlocks are in place to protect the system objects 3 2 1 5 Safety Interlocks The final level of interlocking is the safety interlock Safety interlocks perform the same function as a protection interlock but over a number of objects that surround where the interlock was triggered in the system A safety interlock such as the emergency stop push button creates a safer environment for anyone working on the process level 3 2 2 General A number of interlocks are applied to each object generally so they can be systematically safeguarded from failures These are the interlocks that involve a common feature of all objects such as the communications They include gt Profibus Master Communications Unhealthy inhibit interlock given to every device on the Profibus DP PA network gt DeviceNet Master Communications Unhealthy inhibit interlock active on all DOLs gt Group Crash Stop If objects in the same group all crash simultaneously this will cause all the objects to be interlocked Inhibit interlock active on all devices excluding some valves gt Drive Main Isolator Unhealthy protection interlock each drive either DOL or VSD wil
18. Mode Manipulated Device s Cyclone Feed Man Auto CAS FIC6604 2 neen Heen Man Auto FV6604 Man Auto SES une me manato me e nes mem wins mm nn mem Wein SE Man Auto ne 0 Man Auto nz Classifier Man Auto FV6636 Man Auto FV6637 Man Auto FV6638 4 Man Auto FV6639 Spiral 15 LIC6635 Man Auto LV6635 Man Auto FV6665 Man Auto PU282 Man Auto FV6667 LIC6665 LIT6665 Man Auto FV6668 Thickener 20 LIC6700 LIT6700 Man Auto PU289 PU290 LIC6711 LIT6711 Man Auto CAS FIC6604 Sch Engineering Internship Terry Gittos 11 1 2013 22 DIC6731 6734 Man Auto S 23 pice Pie Man Auto S 24 nemi Pied Man Auto J S 25 nee Pieige Man Auto FV6706 26 mem mem Man Auto Pu296 OO Tailing Disposal LIC6771 LIT6771 PU291 292 293 LV6771 Desands Water Services 28 Fices5 T6755 Mani FV6754 29 uc6e75t Wien Mani Wein _ 20 PIC6752 Preis Man Auto PU256 298 299 32 L1C6755 1176755 Man Auto Less Table 3 List of PID loops for the desands upgrade No PID Name PV Sensor Mode Manipulated Device s Scrubbing Scrubbing O a neem mm me en mm mes mn e mm mn me mm en s ean men mp en O mme me me es e me mem mm en nmn men mm en e men mes me es mm mon am mme mn men am mmm se wm we amo mmm mn um me om nm s ews mmm nm oan U mmm mmm om mam Table 4 List of PID loops for the wet scrubbing upgrade 32
19. Wosst gt ENG450 Engineering Internship FMG Wet Front End Final Report Student Terry Gittos Date 3 5 2013 Version 1 1 Declaration All of the work contained in this document is the work of the author unless otherwise stated and referenced This document in its entirety adheres to the plagiarism policy outlined by Murdoch University solemnly declare that to the best of my knowledge no part of this report has been submitted here or elsewhere in a previous application for award of a degree All sources of knowledge used have been duly acknowledged Engineering Internship Terry Gittos 11 1 2013 I Acknowledgements would like to offer my sincerest gratitude to the staff at Murdoch University The dedication of my lecturers has seen me emerge as a talented graduate with a vast array of instrumentation and control knowledge In particular would like to highlight the work of Dr Linh Vu and Associate Professor Graeme Cole Linh drives the fundamentals of physics and mathematics into all areas of the Instrumentation major and is an inspiration to me Graeme is the master and commander of a unique course which involves connecting the electrical computer world with the physical world If he passes on a fraction of his electrical knowledge will benefit greatly believe the course have undertaken will set me apart from other graduates and make me a highly valued member of society would also like to offer thanks
20. accessed 11 2012 27 Gfk1504k Versamax Datasheet accessed 11 2012 28 Gfk1503D Versamax Datasheet accessed 11 2012 29 Drum Scrubber http www durgametals com drum scrubber html accessed 8 2012 30 Motherwell Cimplicity Guide http www motherwell net au Uploads Images cimplicityhmicutsheetgfa16 O 1 pdf accessed 11 2012 31 http www plcengineers com plc vs pac html accessed 3 5 2013 62
21. and Cimplicity Both Microsoft Excel and Cimplicity have the ability to generate classes and objects that have a specified amount of points linked to the PLC Instead of generating each object with a large amount of points and filling it in using the Cimplicity points view which can be tedious all the objects points can be exported to a CSV file This is done by the following steps 1 Open the command prompt 2 Get to the project directory and into the master file eg C Proficy Cimplicity MyProject Master 3 Use the command clie export MyExportfile csv 4 This will export all the objects on the project unless a filter is used A common filter is Sp PU which will only select objects that contain the letters PU such as the pumps class eg PU266 5 This objects file can now be opened in excel where it is relatively easy to fill out the required descriptions alarms constants ect 6 Once completed save the file and import it back into the master file directory using the command clie import MyExportfile csv The ability to export and import CSV files saves time and is a vital skill to have when working with Cimplicity 49 Engineering Internship Terry Gittos 11 1 2013 6 Network System Components such as hardware and software make up the bulk of a PCS Data is still not free to move without a communications network that caters to the customized system In this section the layout of the physical communica
22. are placed on the right with switching conditions in between Conditions are set between the active side and the coil When the conditions are met the coil which can be a system output is activated Figure 4 3 1 was included to give a feel of the ladder logic and how it was written in the project There are significantly large amounts of ladder logic in the project and some parts such as that shown in Figure 4 3 1 are simple and some are much more complex The functions used in this figure are common the Machine Edition software and perform a relatively simple tasks 40 Engineering Internship Terry Gittos 11 1 2013 PBMstr1 PBComHty PBMstr2 PBComEt AG261 DOLE nntoinsts 96 H d 97 gaff Drive Inhibit Alarm 4 98 gaff DeviceNet Master Communications Unhealthy 99 gaff Setthe alammask AG261 DOLTIOTM AG261 DOLTInhibIntM 100 Lt M DEMstriFNSts AG261 DOLTinhibInests 101 Li Hp 102 Filter the status bits through the alann mask to determine dam states MOVE BOOL NOT WORD MOVE BOOL MOVE OINT 16 1 i D 1 AG261DOLTInhibIntst IN a w O AG26tInhbIntFit01 AG261DOLTIInhbIntM IN o w Q AG26tnhibIntMask01 Reset trailing edges of any current alam ANDWORD 1 AG26tInhibIntFiltot INI D AG26MInhibIntFiltHist01 AG26IInhibIntFiltHisto1 JIN2 Fig 4 3 1 Some ladder logic code as used in the project In addition to activating a Boolean output c
23. ch as corrosive resistance 8 1 3 Engineering Project Management In addition to creating the three prime internship documents the undergraduate had access to a number of project management documents These include design plans cost analysis tender documents and project scope documents Anything not filled in by these documents was discovered through client liaison during the FAT Effective project management was achieved in this project and an impression of this was received by the undergraduate 8 1 4 Engineering Operations This area involves working in an engineering team to complete engineering work Engineering work is generally complex and requires significant planning thought and accurate execution Having a team gives the solution a higher chance of success This is because engineers can take on a task from the project where their personal specialization lies Watching and learning from senior engineers that do this helps an undergraduate develop good engineering practices 8 1 5 Self Management in an Engineering Workplace Professional skills are necessary to integrate successfully into a workplace An adaptation has to be made when entering to what is arguably an alien environment Ultimately dress and interpersonal behaviours have been set to higher standards 8 1 6 Investigating and Reporting This project has been thoroughly investigated This should happen with every project undertaken as a good design can only stem from
24. ction is overseen by a senior member of Motherwell Automation and must satisfy the company s codes gt Display Tests The main area of testing occurs in the field Testing also occurs in the control room since remote operations are to be achieved as part of an effective PCS Each hardware test usually has a corresponding alarm or visible change within the SCADA which can be used to test the display gt Functional Tests As written each operation is performed one by one and the outcome is recorded Any discrepancies must be solved before moving on A number of SAT documents must be drawn up for this project since there are many items to test and it is easier to test all items of the same class at the same time 7 4 OPERATION MANUAL Upon completion of the SAT the integrated system is ready for delivery When this is the case a final document is produced that details the PCS and how to operate it This is similar to a custom manual but also includes references to any documents that may help should there be any problems in the future The operations manual highlights the correct operating procedure and normal operating ranges This document is deliverable to the process engineers as well as senior management 53 Engineering Internship Terry Gittos 11 1 2013 8 Outcomes It is difficult to sum up just how important experience is to a young engineer An engineering internship is a huge source of experience that rounds o
25. ction of the plant that fits in between the infeed and the screening A new RX3i unit was used for the control 25 Engineering Internship Terry Gittos 11 1 2013 system This is PLC 5071 Many objects were included as part of this code Some of these objects or machines were significantly more complex than previously worked on These include 2 4 3 1 Scrubber 1 DOL Pumps PU301 309 The ancillary pumps for the scrubbing machine DOL Heaters HE201 206 The lube heaters for the gearbox and the main bearing DOL Inching Drive GB214 The drive in charge of breaking the locked charge as mentioned in control philosophy DOL Screens SN214 and SN224 To size the ore after it passes through the scrubber VSD CV214 BF214 SB214 and PU224 Scrubber 1 conveyor scrubber 1 belt feeder scrubber 1 drive and the fines screen underflow pump Digital Valves SV6101 SV6149 54 FV6162 66 and SV6161 All scrubber 1 support and ancillary valves Control Valves FV6120 23 and FV6160 To control the water added to each section to ensure a viscous flow 2 Scrubber 2 DOL Pumps PU311 319 The ancillary pumps for the scrubbing machine DOL Heaters HE207 212 The lube heaters for the gearbox and the main bearing DOL Inching Drive GB215 The drive in charge of breaking the locked charge as mentioned in control philosophy DOL Screens SN215 and SN225 To size the ore after it passes through the scrubb
26. d SCRCCINS EE 49 6 Network SYSTEM isa ist ereta aiii dd di a das a dd 50 6d L t uge genge eege KEE ENEE dane AEN EEN ande E ideia do 50 Z Documentation Ee ee E Peis anda OE Pee aad canal eer dar 52 7 1 Detailed Design Specification ue ENKEN EERSENNR NENNEN Ne EEN ckedeees canes 52 7 2 Factory Acceptance Test 52 7 3 Site Acceptance Test ex tt NENNEN KENE NNN NEE KENNEN VER nana 52 7 4 Operation Mana seers ge EE Eed EE 53 O OUTCOMES EEN 54 8 1 Achievements ue ege ere re 54 Ser e et E EE anima ureseemnd 56 EE gt eee ee een Res ee ore eee ee eee een meine a E anne 57 9 1 Standards and COGS EE 57 9 2 Versamax E UE 58 9 3 E EE 60 10 Bibliography raspas ES Mp O AS AS a ra 61 Engineering Internship Terry Gittos 11 1 2013 IV Table of Figures Figure No Description Page No Figure 1 2 1 Motherwell Logo 12 Figure 1 3 1 1 Map with Cloudbreak mine site 13 Figure 2 2 1 Flow diagram of Plant pre upgraded 16 Figure 2 2 1 1 Desands section overview 17 Figure 2 3 1 1 RX3i PLC 19 Figure 2 3 5 1 ABB ASC800 wall mounted drive 21 Figure 2 3 6 1 CEP7 overload relay 22 Figure 2 4 1 4 Upgraded desands overview 27 Figure 2 4 2 3 Industrial scrubber machine 30 Figure 2 4 2 4 Wet scrubbing section overview 31 Figure 3 1 1 PID SCADA example 1 32 Figure 3 1 2 PID SCADA example 2 32 Figure 3 1 3 PID SCADA example 3 33 Figure 3 1 4 PID SCADA example 4 33 Fi
27. d system and configuration information Overall the package was easy to use and had some valuable features This includes the toolbox feature The toolbox is a server set up for storing function blocks that have been created either by GE IP or Motherwell s in house team This means that anyone that can access the server can import the most up to date blocks to the project they are working on 4 1 1 Training Motherwell Automation has a training division that supplies external companies with the basic introduction on GE IP software and hardware In the opening weeks of the internship specific training on this software was supplied to the intern This training includes configuring and connecting to a PLC Most areas of PLC functions were covered in the course ENG305 PLC Systems but other functions like Ethernet Global Data EGD and toolbox were new to the intern Ethernet global data is a function of the PLC to communicate with other PLCs that share a physical connection through an Ethernet protocol cable This made the training a worthwhile experience 4 2 PLC CONFIGURATION Configuring the PLC is a task that requires knowledge of all items on the rack A rack is a twelve slot backplane that has interchangeable PLC modules The basic PLC requires that there is a power supply and a CPU module Since most of the I O was received though a Versamax unit the racks each contains at least three communication modules The following screenshot encaps
28. e plate that allows other hot swappable modules to be selected and fitted Any of the modules fitted can be redundant including the CPU and or power supply PACSystems RX3i POWER SUPPLIES CPUs sR sae hip ee Fig 2 3 1 1 An RX3i BASEPLATES MOTION MODULES rack with various attached modules 24 DISCRETE UO MODULES EXPANSION MODULES PNEUMATIC MODULES 16 Engineering Internship Terry Gittos 11 1 2013 2 3 1 1 I O Modules There are a number of ways to deliver the I O to the CPU for an RX3i unit This is referred to as a PAC The difference between a PLC and a PAC is the functionality networking options and expandability has been significantly increased in a PAC The role of the PAC is changing and merging towards the combined function of a PLC RTU and a DCS 31 The I O modules available to this unit are e Discrete I O Module Attaches to the base plate and is hot swappable Inputs commonly use switches buttons proximity sensors and BCD thumbwheels Outputs used consist of relays contactors BCD displays and indicator LEDs e Analogue I O Modules Also hot swappable and used with sensors and actuators e Distributed I O Communications modules provide options for distributed I O Choose from Ethernet Profibus DP Genius Bus or DeviceNet 2 3 1 2 Specialty Modules Specific application requirements may make it necessary for these modules to be included There are the millivolt and
29. e transmitter Siemens instrument It is highly accurate and user friendly The Sitrans DS3 uses Profibus PA as a communications protocol 21 2 3 8 7 Sitrans PLU The Sitrans Probe LU is an ultrasonic level transmitter It uses time of flight based calculations to determine the level of up to 12m It can also be used to calculate volume and or flow rate The sensor can be connected to a PCS via Profibus PA 21 2 3 8 8 Disocont The Disocont is an embedded system used as a part of the conveyor belts They provide the necessary scaling and output for mass travelling ona conveyor into a bin They are connected to a load cell or other weight measurement device then serve on the Profibus PA network 22 2 3 8 9 WIKA Temperature Transmitter The T53 temperature transmitter is a dual functionality sensor The user must define the specific functionality using the input settings on the Pail Engineering Internship Terry Gittos 11 1 2013 transducer block The transducer block has both an RTD and thermocouple Profibus PA can be used to network this device 2 3 8 10 Magflow 6000 The Magflow 6000 is a Siemens magnetic flowmeter sensor It uses an electromagnet and calculates to flow from the voltage induced The requirement for this is that ions exist in the liquid Iron ore slurry will have no problem generating this voltage These sensors can use Profibus PA DP or DeviceNet 20 2 4 DETAILED UPGRADE SPECIFICATIONS The cli
30. eak Detected gt lt 4 Equip N 9 E Tailings Low Power Equip No Unconfig Unconfigured HH 4 4 configured HHHH H 4 Tailings Gland Water Booster Pumps Unconfigured asma ss Donfigured g 4 J Equip No El Unconfigured gt 7 B BD Unconfigured TASA Flush on Shutdown Uncohfig Uncoi ef Start or Extend Flush Unconfigured Unconfigured HHHH HH Unconfigured HHHH HH perto Equip No Unconfigurec Unconfigurec TK260 Unconfigurec Fig 3 1 3 A more complex PID loop shown in the SCADA In this screen the dotted white lines shows the information transfer of the PID loop It manipulates a control valve as well as the outflow pumps This is due to the fact that not only the level of the tank must be controlled but also the density of the material in the outflow Additional sensors must be to determine this and fed to the controller 30 Engineering Internship Terry Gittos 11 1 2013 Unconfigured Contro mode Unconfigured OV H TS I Unconfigured Unconfigured OV_Hyperlink Unconfigured Unconfig Fig 3 1 4 An alternating PID loop In the above scenario the pump speed can be controlled by either a set point on the outflow rate or the density of the process material further down the system In cases where the density cannot be measured it is calculated using other sensors The PID loops included in the upgrade are listed in the tables below No PID Name PV Sensor
31. ed to control conveyors and pumps They are used to control the speed of these items to a set point ABB drives are designed to handle the high power requirements of the process industry Unlike most VSDs that use variable frequency the 18 Engineering Internship Terry Gittos 11 1 2013 ACS800 uses direct torque control DTC 12 DTC provides a high starting torque as well as accurate control of speed and torque The exterior of the ASC800 is designed to withstand harsh environments by a combination of mechanical design and material selection To models of the ACS800 VSDs can be seen in Figure 2 3 5 1 They must be first mounted to the wall then wired to the motor or other AC equipment to suit specifications and requirements a Fig 2 3 5 1 A pair of wall mounted ACS800s 12 OO 2 3 6 CEP7 Overload Relay amp DNY42R Starter The CEP7 is a solid state microprocessor based overload relay designed for the protection of induction motors 13 For the motors connected to these there is no variable speed The motor will either be on and running at the specified rate or off This kind of relay must be used in between the field AC and computer control system DC The functions of the CEP7 are connected to the PLC which includes e Overload Phase loss trip only e Stall trip only e Jam e Underload e Current imbalance e Number of starts e Operating hours 19 Engineering Internship Terry Gittos
32. elationship between objects like a VSD pump and a drain valve 4 4 1 Client test teams For the FAT testing FMG sent some test engineers to check the code alongside the Motherwell engineers The testing was done in pairs with one engineer from each company This team testing certifies that testing will be more accurate since someone who writes the logic may be unable to see its flaws Many objects need to be tested so three teams were testing simultaneously Each team was also given a SCADA support member to quickly debug any differences in the Cimplicity and to aid in client satisfaction 44 Engineering Internship Terry Gittos 11 1 2013 5 SCADA System System automation is a very modern approach to solving an industrial process The human element however cannot be omitted in such a complex array of subsystems SCADA allows process engineers to stay involved in the process even though it is automated This allows them to fine tune the process for maximum productivity A SCADA system was required as part of the work scope for the project 7 This system was set up on the existing software for the facility Cimplicity 7 5 Fig 5 1 A management view of where the SCADA system sits in any business that can use it 30 The Cimplicity software exists in the process execution and supervisory control level It can be connected to one of the upper levels although this is not a requirement Engineering Internship Terry Gittos
33. ent has already designed the upgrades to the process facility These have been mapped in a series of P amp IDs Any extra design requirements have been filled in on the design specifications handbook which was provided by FMG along with the P amp IDs Upon examination of these documents Motherwell Automation set out to design and implement the process control system Converting the written request of the client into a well designed PCS is a difficult task The basic functionality must be achieved and the finer points must all be ironed out P amp IDs are technical diagrams that accurately express the location of sensors and actuators to be used in the PCS P amp IDs are used as the master source of information This means that where a written document is seen to conflict with the information on a P amp ID the written document will be overruled by the P amp ID The following PCS design was created using client documents in this manner 2 4 1 Tag Names Tag names are used throughout the industrial industry They aid in designing large scale projects where the amount of objects used quickly exceeds the amount that most people can keep track of They start with an abbreviation of letters and end with numbers The letters indicate what type of object while the numbers indicate placement and reference to other objects of that type 2 4 2 Desands Area The desands section has four existing PLC units These must be altered to accommodate new equipmen
34. equired information from the PLC or other device Engineering Internship Terry Gittos 11 1 2013 The work for each project is created in the editor known as Workbench This provides thumbnails of all the screens created classifies the screens into sections of the project and creates and manages objects and alarms A screen shot of Workbench can be seen in Figure 5 1 2 ee Fig 5 1 2 The workbench Ter interface makes it easy to construct a project SCADA The layout is such that navigation can is ina window on the left and screenshots of the actual pages are in the window on the right 5 2 EXISTING SCREENS The plant has already been in operation for some time and the software used for SCADA was Cimplicity 7 5 The latest current version is Cimplicity 8 2 This means that while working on this project it was important to have the correct software version since screens saved in a newer version cannot be used in a past version When a facility is upgraded such as FMG Wet Front End is developed the company will opt where they can to keep the current software as it saves the cost of reprogramming the existing material The previous Cimplicity screens were delivered to Motherwell for this purpose The entire older section of screens could be altered rather than recreated and the style of the SCADA could be kept for the new sections of the plant The types of screens created for this projec
35. er VSD CV215 BF215 SB215 and PU225 Scrubber 2 conveyor scrubber 2 belt feeder scrubber 2 drive and the fines screen underflow pump Digital Valves SV6201 SV6249 54 FV6262 66 and SV6261 All scrubber 2 support and ancillary valves 26 Engineering Internship Terry Gittos 11 1 2013 Control Valves FV6220 23 and FV6260 To control the water added to each section to ensure a viscous flow 2 4 3 3 Scrubber 3 DOL Pumps PU321 329 The ancillary pumps for the scrubbing machine DOL Heaters HE213 218 The lube heaters for the gearbox and the main bearing DOL Inching Drive GB216 The drive in charge of breaking the locked charge as mentioned in control philosophy DOL Screens SN216 and SN226 To size the ore after it passes through the scrubber VSD CV216 BF216 SB216 and PU226 Scrubber 3 conveyor scrubber 3 belt feeder scrubber 3 drive and the fines screen underflow pump Digital Valves SV6301 SV6349 54 FV6362 66 and SV6361 All scrubber 1 support and ancillary valves Control Valves FV6320 23 and FV6360 To control the water added to each section to ensure a viscous flow The naming conventions between scrubber objects are very similar In most cases a single number change in the naming convention will show which scrubber that particular item belongs to Other areas of this section also have objects such as VSD CV123 CV125 and CV128 The prod
36. er another screen is included to show the status for the CEP7 and DNY42R Valve Screens A single screen that shows interlocks and diagnostics Manual or automatic operation Sequence Screens These screens operated a sequence of events in automatic mode They display which function are occurring at each section of a sequence in the form of a Boolean matrix Fig 5 2 3 A sequence matrix screen pn Oster OVERVIEW Le RR RER tenons RER RER REH sucos meros ER ER EE OVERVIEW E LT PU023 Process Water 2 Pump A Engineering SP amp GRPScrT3 CimEdit Ele Edit View Format Tools Frame Help Oe 6g osm KES YN CEO Ae Alass aD Sage Wow agem OVERVIEW 48 Engineering Internship Terry Gittos 11 1 2013 5 3 OBJECT ORIENTATED SCREENS When creating a screen for an object it may be easier to create a generic screen that includes all possible points that a class of objects can have for example the pump interlock screen Then through Cimplicity software the points may be connected to a specific object of that class and the reference points will be filled in automatically This way each VSD pump in the SCADA can essentially be copy pasted saving a vast amount of time Having object orientation in the SCADA is a great advantage and opens up the ability to use spreadsheets to efficiently fill in the specifics to each item 5 3 1 Excel
37. ficiency that FMG expected from a professional engineering firm While the FAT test went largely overtime the experience provided in this test ensures a more systematic approach can be achieved on the next project The true measure of this test is the success of the code when executed on site It is preferable however to have an accurate code rather than save time and send partially complete code to site Writing advanced ladder logic comes with experience The coding language is capable enough to handle the control mechanisms required This task was originally delegated to the undergraduate but then given to a senior 54 Engineering Internship Terry Gittos 11 1 2013 engineer to clean up and peer review This feedback help to develop a learning environment 8 1 2 Materials Components and Systems This area had the largest level of knowledge distributed The project equipment section of this document can give an indication of just how many new components were discovered While the university pushes a practical foundation it is impossible to cover all components used in the industry The systems used in this project were covered in detail They can be applied to many industrial applications and using them was a great learning experience The materials are simple in nature Ore water slurry and thickener keep the objects used relatively generic This means that the engineering materials used do not need advanced traits su
38. good 55 Engineering Internship Terry Gittos 11 1 2013 understanding The three reports and the corporate documents make up the reporting for this document Together they can deliver very detailed knowledge about the works undertaken 8 2 CONCLUSION The final contribution an engineering student must make is an engineering thesis or internship Motherwell Automation has taken on the undergraduate and presented the project FMG Wet Front End as the subject matter This project was worked on by a team of engineers from Motherwell and largely involved the majors of study in particular industrial computer systems engineering Motherwell s friendly technical staff are ideal for introducing a young professional into the post university world This project successfully provided the undergraduate with a fantastic education on industry operations 56 Engineering Internship Terry Gittos 11 1 2013 9 Appendix 9 1 STANDARDS AND CODES All equipment and works shall comply with the current applicable Australian standards unless otherwise stated in contract documents Should no Australian standard be applicable the works shall conform to the following standards unless otherwise stated in contract documents 1 International Standards Association 2 ASME 3 AGMA 4 British Standards 5 CEMA 57 Engineering Internship Terry Gittos 11 1 2013 9 2 VERSAMAX MODULES Input Module 120 VAC 8 Poirits C200MDL 1
39. gure 4 1 1 Proficy Machine Addition Interface 41 Figure 4 2 1 Typical PLC hardware configuration 43 Figure 4 3 1 Ladder logic example 43 Figure 4 3 1 1 PLC function blocks example 44 Figure 4 4 1 FAT document map 45 Figure 5 1 Management View for PCS 47 Figure 5 1 1 Example Cimplicity screen 48 Figure 5 1 2 Workbench Interface 49 Figure 5 2 1 Overview screen 49 Figure 5 2 2 Interlock and control screens 50 Figure 5 2 3 Process sequence screen 50 Figure 6 1 1 Network Overview 53 Engineering Internship Terry Gittos 11 1 2013 V List of Tables TABLE 1 RANGE OF CONTROL EQUIPMENT 16 TABLE 2 PLC COLOUR CODING 25 TABLE 3 LIST OF PID LOOPS FOR THE DESANDS UPGRADE 32 TABLE 4 LIST OF PID LOOPS FOR THE WET SCRUBBING UPGRADE 32 Engineering Internship Terry Gittos 11 1 2013 VI Table of Symbols and Abbreviations Abbreviation Symbol Meaning FMG Fortescue Metal Group 1 0 Input output ICE Instrumentation and Control Engineering ICSE Industrial Computer Systems Engineering FAT Factory Acceptance Test SAT Site Acceptance Test PLC Programmable Logic Controller HMI Human Machine Interface SCADA Supervisory Control And Data Acquisit
40. in Wilde Engineering Project Control Engineering Management Journal ISSN 0960 7919 1995 Volume 5 Issue 6 p 279 accessed 10 2012 7 Basis of Design 005001 0000 1000 STD 0001 Cloudbreak Enhancement Project Internal Document accessed 11 2012 8 P12035E11001 005 Desands and Water Services FAT Procedure Internal Document accessed 11 2012 9 P12035E04002 006 Wet Scrubbing Detailed Design REVOO2 Internal Document accessed 11 2012 10 P12035E11002 014 SCUBBING FAT Procedure Internal Document accessed 11 2012 11 P12035E04001 004 Desands and Water Services Detailed Design REVOO1 Internal Document accessed 11 2012 12 ABB Drive manual accessed 11 2012 13 CEP7 C1 C2 C3 C5 User Manual accessed 11 2012 14 DNY42R Manual accessed 11 2012 15 DeviceNet Operation Manual accessed 11 2012 16 Samson 3730 Datasheet accessed 11 2012 61 Engineering Internship Terry Gittos 11 1 2013 17 Vibromac 107 Datasheet accessed 11 2012 18 ABB Level Transmitter Datasheet accessed 11 2012 19 Endress Hauser Pressure Transmitter Datasheet accessed 11 2012 20 Magflow 6000 Datasheet accessed 11 2012 21 Sitrans DS3 Datasheet accessed 11 2012 22 Disocont Datasheet accessed 11 2012 23 Profibus Planning Manual accessed 11 2012 24 Pac Systems RX3i controller Design Manual accessed 11 2012 25 Gfk1533 Versamax Datasheet accessed 11 2012 26 Gfk1534b Versamax Datasheet
41. ion CCR Central Control Room VSD Variable Speed Drive PC Personal Computer PCS Process Control System P amp ID Piping and Instrument Diagram DOL Direct On Line EGD Ethernet Global Data GE IP General Electric Intelligent Products PAC Programmable Automation Controller CSV Comma separated values Engineering Internship Terry Gittos 11 1 2013 1 Introduction 1 1 DOCUMENT INTRODUCTION This document provides an overview on the work done for Fortescue Metal Group FMG by Motherwell Automation as part of an engineering internship at Murdoch University The project is named Wet Front End Expansion and refers to and upgrade of the processing facility at Cloudbreak mine site A team of engineers was assembled to complete the automation for this upgrade The student was positioned as part of this team The current facility is operational and yet not optimised The plant is to be altered in such a way that increases the quality of the ore This means that new objects pumps control valves motors compressors and digital valves are required to be installed and automated Each of these objects may be part of an electrical control system and electrical monitoring coupled with a user friendly interface This task is the main objective of this project and includes many aspects of the Industrial Computer Systems Engineering ICSE and Instrumentation and Control Engineering ICE majors During this project a range of hardware and sof
42. is adjusted is dependent on the PID variables These variables are set in the blue green block in the SCADA This is a standard control algorithm or loop In addition to general PID feedback control the project required more complex control loops such as the cascade control shown in Figure 3 1 2 Once again this is more of a data direction indication that can be used to help identify what is going on froma control theory perspective 29 Engineering Internship Terry Gittos 11 1 2013 Fig 3 1 2 A cascaded PID loop The figure to the right shows a difficult cascaded loop This means that the process variable that is the level of the tank uses an inner loop involving the flow rate The combined calculation of these determines how much the control valve is opened or closed This will in turn change the flow of the water which also has the effect of changing the level of the tank This idea is thoroughly explored in the unit ENG304 Advanced Process Systems La Flush on Leak Detection Else Trip 1XX A Equip No y Unconfigured LA Bypass Low Power Condition Equip Ni j Unconfigured Saup PS HHHHH H HHH 4 Bypass Low Flow Condition A Ls F Unconfigured a E H tHE E LV2707 Open Time Exceeded 7 Min Flow SP Reached Pr d Equip N Unconfigured E Tum On Tailings Pump E Min Act Time Reached Equip es EES E Tum Off Tailings Pump E Tailings Leak Detection et Sapa E Tailings Low Flow E Tails L
43. it Input Current 4 Channels and Output Current 2 Channels IC200ALG430 IC200ALG432 Engineering Internship Terry Gittos 9 3 11 1 2013 GLOSSARY Word Meaning Transmitter Used in the sense of a device that transmits data observed sensor Optimised To make something as effective as possible Interlock Connection so that different inputs can affect the outputs Scope The range of actions or requirements Algorithm A step by step procedural method to solving a problem Analogue Variable in reference to a measured value Solenoid Electrical switch that is closed when power is received Logic A system of reason that follows specific rules Server A CPU set up to answer to a master CPU A collection of data usually in a server arranged for ease Database and speed of search and retrieval Network A system of communications that interconnect 60 Engineering Internship Terry Gittos 11 1 2013 10 Bibliography 1 Motherwell Automation Website http www motherwell net au accessed 8 2012 2 Equipment Specification 500CB 00000 SP IN 0004 Cloudbreak Enhancement Project Internal Document accessed 11 2012 3 Terry Gittos Progress Report FMG Wet Front End 2012 accessed 11 2012 4 Terry Gittos Project Plan FMG Wet Front End 2012 accessed 11 2012 5 Control Philosophy 500CBP0001 02059 PH IN 0002 Internal document accessed 11 2012 6 Edw
44. l have this interlock The isolator is triggered which will naturally prevent power from entering the drive 34 Engineering Internship Terry Gittos 11 1 2013 gt Drive Main Contactor Unhealthy protection interlock the contactors used are equipped with fault sensors that will be passed on to the PLC creating this interlock gt VSD Device Status Unhealthy protection interlock all VSDs are equipped with a microcontroller and can determine an error within its function gt VSD Communication Unhealthy protection interlock this represents the Profibus PA failing to communicate to a VSD gt Drive Speed Fault protection interlock VSD does not achieve the set point speed within a set time and reports this to the PLC gt Versamax Communications Unhealthy protection interlock the PLC fails to communicate with a Versamax module gt Emergency Shutdown Relay safety interlock the emergency shutdown has been activated in an extreme case emergency cause all object to stop Every object has this interlock gt Emergency Stop Push Button safety interlock located at various positions around the facility Push buttons can be used in an emergency and shutdown an array of surrounding objects This covers the common interlocks that are included in this PCS There are however vastly more than this See Desands FAT Procedure Manual and Wet Scrubbing FAT Procedure Manual for the remaining Interlocks 8
45. lds the largest tenements of any iron ore mining company in Western Australia These holdings are made up of the Chichester Hub and the Soloman Hub and cover more than 87000 Km FMG s first operational mine is Cloudbreak which is located in the Chichester Hub 1 3 1 Cloudbreak Mine Cloudbreak has been running since October 2007 and produced 28 million tons in its first year of operation The output of this mine site is around 40 million tons of iron ore per annum To better handle the huge production of ore both an ore processing facility and a E railway system to Herb Elliot Port was constructed The assigned project o Cloudbreak Mine involves the processing facility at this site the location of which is shown in Figure 1 3 1 1 Fig 1 3 1 1 Map of Cloudbreak mine site showing its location in Western RF Australia 1 3 2 Iron Ore Processing The aim of the ore processing plant at Cloudbreak is not to refine the ore into metal but rather to produce better quality ore The higher quality the ore the more it can be sold for This is a dry process that includes e Infeed Starting section made up of conveyor belts and bins 10 Engineering Internship Terry Gittos 11 1 2013 e Screening Determines the appropriate path for the size of ore that is screened e Crushing To reduce the size of feed material to enable further processing e Desands To aid in removing impurities from the ore This is a c
46. n of the plant The other will be used to handle the PCS of a completely new section of the plant wet screening and scrubbing Many code changes will be added to the existing eight PLCs in order to facilitate the changes made The full requirement of the PLCs includes all control modes interlocking of equipment alarming and the appropriate networking for relevant data transference both inter PLC and to the CCR 2 1 1 Scope of Work The PCS has many levels of control so that the process engineers who run the facility can operate it optimally This means that the services offered by Motherwell Automation must include but not be limited to e Additional screens to the existing SCADA system to include all new I O graphics objects alarms interlocks and control systems as indicated by the P amp IDs e Configuration of hardware as required by the Ethernet protocol e Configuration of the new PLCs including I O calculations and function block based logic e All necessary PLC coding in ladder logic e Configuration changes to the existing PLCs to tie in to the new sections e Testing of modified configurations e Testing of new configurations e Develop and maintain a server orientated database e Prototype testing of all new equipment including Profibus e Integration of the new PCS 12 Engineering Internship Terry Gittos 11 1 2013 e Safety practices such as multi level interlocking are to be designed and implemen
47. o achieve the technical functionality required for the project Each object will have a different amount of I O which relates to its task within the larger process A list of the equipment is given below 15 Engineering Internship Terry Gittos 11 1 2013 Object Description Digital UO Analogue I O RX3i GE IP PLC unit N A N A Profibus PA Field bus used for communications Variable Variable DeviceNet Field bus used for communications Variable Variable Versamax Blocks Distributed I O units Variable Variable VSD ABB ACS800 256 32 DOL CEP7 overload relay and DNY42R 16 128 N A Valves Digital valves 16 64 N A Control Valves Samson 3730 32 16 Analogues Various sensors and transmitters N A 16 Table 1 Table 3 shows a list of the equipment used for the Wet Front End Upgrade All of the objects are common to process control systems and many were given attention within the unit ENG345 SCADA Systems This was however not specific to the ones used in this project This is no surprise since many of these objects exist from a very large number of vendors and suppliers 2 3 1 RX31 PLC The PACSystems RX3i is the most essential piece of hardware to the project Some of these controllers are already established in the facility since the original install in 2007 The RX3i shown in Figure 2 3 1 1 carries a 1 GHz CPU with 64MB of memory and two serial ports This is connected to a universal twelve slot bas
48. of work involved designing the SCADA or human machine interface that the future process engineers at FMG would use This was the majority of work completed by the internship student and this report will indicate this Engineering Internship Terry Gittos 4 11 1 2013 III Table of Contents AcknomwledBementS apr pain pesadas aaa AU ea a ANEN EEN en 2 Executive Summary 3 Table OT Contents TE 4 Table of assumisse Ga RO CAD E DS 6 CEET H Table of Symbols and Abbreviations cccccce cece cece ee ee ee eee eeeneeeeaeeees 8 PAPO CIE TON EE 9 LI DOCUMENT IntroduUttion 4 cocrenccscrw cosas ue alo Eder 9 1 2 Background on Motherwell Automation cence eeeeeeeeee ees 9 1 3 Background on Fortescue Metal Group 10 Project SCOPC eeh Seege dE encase dE deeg RES dE teg 12 2 1 Project e elt EE 12 2 2 Iron Ore Processing Plant sccicsccscissscciesscsssacensiessrecaceceans ERAN Sand Ce 13 2 3 Process Control Equipment erdeg EEN dE 15 2 4 Detailed Upgrade Specifications 0 cece ccce cece ee ee cesses eeneeeeaees 22 Control Philosophy ebe ds ai as ada aa a LU 29 Sul PUD NOOBS pseudo rima asda abadia da Sd a id ad dd 29 3 2 NERT te FE 33 3 3 Special CASES EE 35 PLC SYSTEM WEE 38 AM PLC Software E 38 4 2 PLC Configuration EE 39 ds kadd r LOGIC EE 40 qA NK LEE 42 Engineering Internship Terry Gittos 11 1 2013 5 SCADA SYSTEM TEE 45 Sd Cimplicity Zeg 46 542 EXISTING SCPE NS isecen rely sl vues Nee eeh 47 5 3 Object Orientate
49. oil blocks can be used for manipulations such as moving words of information and performing mathematics Code should be commented wherever possible This allows the programmer to remember the function of the code or another programmer to understand the code The comments can be seen in purple in Figure 4 2 1 Machine edition also offers a number of other programming languages such as script GE IP script or VBA a state machine base language or standard logic text None of these were used due to the specifications given by the client 4 3 1 Ladder Logic Structure The ladder logic for the project is function block orientated Every scan that the PLC performs only reads the code written in main However there is no ladder logic in main only the three main function block Comms_Main_LD AAA_ Devices and Diags make up the key features of this PLCs role in the system These function blocks also only contain other function blocks within them In this way the project can be broken down in to individual devices communications and diagnostics so it is much easier to navigate and debug should problems arise The following figure Figure 4 3 1 1 is a screenshot of the reference navigator again Only this time it is highlighting the function blocks associated with the project 41 Engineering Internship Terry Gittos 11 1 2013 Navigator ax Fig 4 3 1 1 The ladder logic structure e pe meros re using function blocks Main calls D Logic AAA
50. omplex process that involves adding and removing moisture from the ore The finer parts sands are also removed from the ore during this section Ancillaries to this section include a flocculant producer anda thickener e Stacking Another machine drive function that sorts the ore into appropriate sizing sections for transport 1 3 3 Optimisation The previous ore process works well and is suitable for high volume processing However this process is far from optimised As mentioned before it is a dry ore process and yet the Pilbara region of Western Australia has an extensive wet season which can drastically reduce the ore quality produced Running the wet ore caused by either the rain or existing ground water through the current dry ore process also increases the wear on equipment The FMG Wet Front End project is a plan to change the current dry ore processing plant into a wet ore processing plant This will ensure a higher quality of ore is not only produced but maintained year round 11 Engineering Internship Terry Gittos 11 1 2013 2 Project Scope 2 1 PROJECT OUTLINE Wet Front End project involves enhancing the Cloudbreak iron ore processing facility A combined hardware and software solution is required to upgrade the existing process control system Motherwell Automation has proposed a solution whereby two additional PLCs will be added to meet this requirement Of these two one will be placed in the desands sectio
51. pes of interlocks exist in the project The key differences are the actions taken when they are triggered The name of each interlock is a clue to the action taken The following interlock classifications exist in FMG Wet Front End 3 2 1 1 Permissive Interlocks Permissive interlocks are light guards against any failure in the system They are designed to alert the process engineers of any areas of significance sO appropriate action may be taken Permissive interlock when triggered will result in an alarm yet the system is permitted to continue 3 2 1 2 Inhibit Interlocks The inhibit interlock is similar to the permissive however a stronger ramification is imposed When a system object is already running and an inhibit interlock is triggered the object will be allowed to continue and an alarm is activated If however the object has not yet started it cannot be 33 Engineering Internship Terry Gittos 11 1 2013 started if an inhibit interlock is triggered In this way the object is said to be inhibited from starting 3 2 1 3 Process Interlocks Process Interlocks are hard stops to prevent any damage to the process system They focus on how the process operates and uses information from the past area and the future area of the process to stop an object When triggered a process interlock will stop an object from running and prevent it from starting Alarms will also be activated on the SCADA 3 2 1 4 Protection
52. pgrades and all other technical aspects of the project A good understanding of the client s needs is required to complete such a document This document is used as the basis for logic and all engineers actualizing programming are required to reference it 7 2 FACTORY ACCEPTANCE TEST The factory acceptance test document has been covered in the PLC System section Its structure is such that all test components are listed and many tables are created so the testers can easily tick them off as they go This document is required to be completed before the code can be transferred to site 7 3 SITE ACCEPTANCE TEST The site acceptance test document covers all connections to the onsite equipment It tests the circuits safety and functionality of the PCS This document must also be checked off while completing the test It is structured into four parts These are gt Overview Specifically informs all personal of the purpose of the test where the test is performed and how including specifying the software 52 Engineering Internship Terry Gittos 11 1 2013 gt Entry Criteria Clearly states all the actions performed before the test can take place An example for this is a known fault that fails the test The test can still be conducted provided that this fault is waived in writing by the client Other entry requirements include that the test will satisfy its function and that no safety risk is violated This se
53. project FMG Wet Front End has been established Two main areas of the process facility are to be upgraded in accordance with the new process Amongst this large scale project are specified control aspects that strongly relate to Instrumentation and Control Engineering The major offered at Murdoch University supports these operations and is a large advantage to any student who works in automation 3 1 PID LOOPS The PID loops are the most common control algorithm used in this project They are essential to the correct function of the plant and are included in the P amp IDs and hence the SCADA An analogue sensor will transmit some information to the PLC which then performs a calculation and alters a connected variable The variable used often a control valve will then cause a change to the system so the sensor reads a desired value or set point Figure 3 1 1 gives an indication of the control philosophy from an interface It indicates the path of data transferred which makes control loops possible rather than showing how they actually function Process Water Unconfigured _ Jnco nfigured PU232 Underpan Slurry Fig 3 1 1 A simple PID loop as seen in the SCADA system Figure 3 1 1 shows a simple PID loop The analogue sensor determines the flow rate of the water If this rate is different from the desired rate set point then the valve is adjusted accordingly The path of information is given by the dotted white line How much it
54. rate fine waste before sending the ore to the classifier e Classifiers specialist equipment that grades the ore to more accurately separate waste and bypass high quality ore straight to the stacking e Tanks a variety of functions can be used with process tanks Common purposes include mixing heating cooling and controlling density e Spirals concentrators These are gravity based devices that separate light density sandy materials from heavier density materials As the ore travels down the spiral the denser material hugs the inside lane so to speak With all these items it is easy to see how each module performs the task of separating the product from the waste Understanding the items helps to design an effective control system 2 2 2 Material Recovery The waste also goes through a process called thickening Thickening has an ancillary section that produces flocculant Flocculant is a liquid thickening agent This is produced and then delivered to the thickener in addition to the waste material The combined waste is then pumped to the tailings dam While the product ore is significantly more profitable the resulting waste ore in the tailings dam can still turn a profit and will often be re mined when the price of ore is sufficiently high 2 3 PROCESS CONTROL EQUIPMENT The project scope has been outlined previously This section highlights equipment that is used in the PCS These objects were connected together t
55. run correctly should operate as follows 1 Two inner solenoid valves are energized 2 The spray door solenoid valve is energized 3 Six successive sprays are metered onto the ring gear During this operation certain conditions must be met The third valve must open no more than 10 seconds after the first two The pressure of the spray is measured and must remain above a certain point for all six sprays If these conditions are not met then the grease cycle fail count increases by one If the grease cycle fail count is equal or greater than five then a protection interlock is triggered on the scrubber 36 Engineering Internship Terry Gittos 11 1 2013 3 3 1 4 Bearing Oil Seal System The bearing oil seal system regularly releases a metered amount of oil onto the main bearing seal located in the pinion The function is controlled by two metering switches and a solenoid valve An oil seal is considered successful when seven counts of each metering switch have been activated If the oil seals has not completed after two minutes of operation the oil seal fail count is increased by one When the oil seal fail count is more than five a protection interlock is triggered on the scrubber 3 3 1 5 Locked Charge Protection A locked charge is a result of ore slurry having rested for a period on the bottom of the scrubber and getting stuck to that area on the scrubber In normal operation as the scrubber turns the slurry flows through and
56. t A wet process will use more pumps instead of conveyors since the ore can now be considered liquid slurry Major changes to this area include adding a module module 4 adding a thickener 22 Engineering Internship Terry Gittos 11 1 2013 thickener 2 an extensive water supply system and changing the desands input to a cyclone feed tank See Figure 2 4 1 4 for the full changes 2 4 2 1 PLC 4262 This PLC contains the code that controls and monitors module 1 It will have the following objects added Pump 232 The dewatering screen pump module 1 Pump 266 The spirals conservation pump module 1 2 4 2 2 PLC 4263 This PLC contains the code that controls and monitors module 2 It will have the following objects added Pump 234 The dewatering screen pump module 2 Pump 269 The spirals conservation pump module 2 2 4 2 3 PLC 4302 This PLC contains the code that controls and monitors module 3 It will have the following objects added Pump 236 The dewatering screen pump module 3 Pump 272 The spirals conservation pump module 3 2 4 2 4 PLC 4303 This PLC is a new addition to the process facility This unit will control module 4 and other new additions such as AG261 The agitator that mixes the cyclone feed tank Pumps 285 286 287 and 288 The pumps that are to become the new desands module feeds one for each module They are connected to the outflow of the c
57. t are Fiocculanes V Jo va e ar omt xen o Ae aut TA s ms gt Overviews Display a large section of the plant with many objects and key indicator displays These build up the foundation of the visual system and must be built to accurately reflect the plant physical layout The control aspects are also shown using the white dotted line Links to other E overview screens help the user to navigate To to a connected area without using the tabs sa aliar pra Fig 5 2 1 The flocculant overview screen e e ee e e e 47 Engineering Internship Terry Gittos 11 1 2013 gt Object Screens Each object inside the overview is interactive and has its own screen that can be entered into upon the user clicking that object This opens up into a two part section The first is the interlock page that displays all the interlocks used by that particular object Each interlock has a Boolean indicator that is green when interlock is not tripped and red otherwise On this page the user can also see the VSD or other analogue values diagnose a problem if any and change the mode of the object manual remote manual local or automatic The second screen associated is the setpoint page where the user can change and or monitor the setpoints for interlocks or controls Fig 5 2 2 Both object screens for a VSD controlled pump in the desands section DOL Screens For a DOL drive the set point screen is smaller howev
58. tation must be maintained at all times All works must conform to the standards given in Appendix 9 1 To aid with this substantial task the client provided all necessary documents These include schedules drawings calculations technical data shipping and packaging details inspection certification and manuals These documents were in turn used to create an appropriate design 2 2 IRON ORE PROCESSING PLANT Upgrading the facility from a wet ore process to a dry ore process requires a large amount of planning and resources Two major changes the desands upgrade and the new scrubbing section apply to the plant and hence associated PCS must be changed installed Each section uses a number of mechanical components that are controlled via a PCS Each component will be mentioned in the project equipment section Figure 2 2 1 below shows the iron ore process sections from beginning to end after the implementation of the upgrade The two section of interest are highlighted purple Fig 2 2 1 A flow diagram of the process facility Upgraded targets shown in purple 2 2 1 Desands As part of engineering design it is always encouraged to break down the problems This exists during the unit ENG305 PLC systems where students are given a gantry crane to program and a similar approach was made for FMG Wet Front End The desands section has already been operating as a three module system Each module is the same and is required due to high 13
59. the network line branch capacity chart length length line length Thick cable 500 Kops 100m Fig 2 3 3 1 The 250 Kops Fs Keer soo ce Thin cable 500 kbps 100m es performance chart Gate D s 15 725 Kops 100m Flat cable 5 Gare D s em Dee 25m 2 3 4 Versamax Units The Versamax units are the distributed I O blocks used in this project They are connected to the PLC via the Profibus DP and the Profibus module on the rack Each module can accommodate for up to 32 points of I O The modules slide on to industrial DIN rail Versamax modules provide automatic addressing which eliminates the need for configuration There is a large range of different I O modules as well as Versamax PLCs and Power units The large range allows the client to custom build the distributed I O Figure 2 3 4 1 gives a birds eye view of a typical Versamax unit The termination points exist on the lower part of the diagram while the connections to DeviceNet are hidden Dim rail is an industrial brass rail with holes in the centre so it can be screwed onto a flat panel Dim rail can be seen in Figure 2 3 4 1 extruding from either side of the Versamax module This shows that it must be mounted on Dim rail Fig 2 3 4 1 On the right is a Versamax I O module with the terminals shown down the bottom 25 See Appendix 9 2 for the full list of I O modules 2 3 5 ABB ACS800 Drive In this project ABB ACS800 variable speed drives were us
60. tions network will be discussed The four main types of communications will be compared The overall network should be designed and operate to complete the PCS solution for FMG Wet Front End 6 1 LAYOUT The top level is where the process engineers directly interact with the PCS These areas are referred to as Stations Cloudbreak process facility has six control stations with six to ten PC computers in each These Stations are connected to each other the PLCs and the historian database servers in an Ethernet ring The Ethernet network has multiple paths in which to travel to effectively bypass any errors in the system The inter PLC communications is also covered by Ethernet however requires configuration of the EGD to be set up Many devices on the PLC network are gateways which communicate to instruments in another communications protocol The DOLs use DeviceNet which is connected through the use of a DNY42R The Versamax remote I O modules use Profibus DP The control valves and analogue sensors use Profibus PA 50 Engineering Internship Terry Gittos 11 1 2013 DATABASE SERVER DATABASE SERVER 89 198 210 1 q 89 198 210 2 EE GLU GOLO GOLA Fig 6 1 1 An overview of the network layout The Ethernet cables in Figure 6 1 1 are shown by the blue lines Likewise the yellow is DeviceNet dark purple is Profibus DP and light purple is Profibus PA Itis important
61. tter is an intrinsically safe sensor that uses RTD or thermocouple to sense temperature It runs on the Profibus PA network 20 Engineering Internship Terry Gittos 11 1 2013 2 3 8 3 ABB Pressure Transmitter The ABB pressure transmitter is rough pressure sensor with a base accuracy of 0 15 and a range of 0 3 to 60000 kPa This hardware is designed to be robust to handle the extreme environments of the process industry 2 3 8 4 Endress and Hauser Pressure Transmitter The Cerabar S pressure transmitter can measure gases steams vapours and liquids It can be used widely in the process engineering industry It uses a ceramic diaphragm that deflects 0 025 mm proportionally to the pressure There is a filling liquid between the diaphragm and a metal sensor creating a resistance bridge The bridge output voltage can then be measured 19 2 3 8 5 Vibromac 107 A Vibromac 107 protects equipment by monitoring the vibration intensity This can serve as a warning for potential hazards The Vibromac is used on vibrating screens in the desands and scrubbing sections and can reduce downtime by creating well timed preventative maintenance The Vibromac 107 utilizes a microcontroller that measures lateral acceleration exciter phase and oil temperature The microcontroller stores the data for up to ten days and creates trending on this data as well as provides a frequency analysis 17 2 3 8 6 Sitrans DS3 The DS3 is a digital pressur
62. tware was used to create a solution for the project This created an effective learning environment and exposed the student to a range of industrial applications in the chosen engineering majors 1 2 BACKGROUND ON MOTHERWELL AUTOMATION Motherwell Automation is an Australian company that was established over 20 years ago This firm operates out of offices in Osborne Park This company has had a strong history in information systems but recently have moved towards the following electrical engineering areas e Networking and communications e Supervisory Control and Data Acquisition SCADA e Process Control and Instrumentation e General Automation Engineering Internship Terry Gittos 11 1 2013 The specialization of Motherwell involves but is not limited to PLC programming and implementation These embedded systems offer complete automation solutions to industries such as mining and resources mineral processing water and waste water oil and gas power and utilities marine rail and road transport bulk materials handling and communications Motherwell has an emerging relationship with Murdoch University since providing internships for a number of students They understand the requirements of an engineering internship and cater to them to the best of their ability 1 3 BACKGROUND ON FORTESCUE METAL GROUP FMG is an Australian Iron Ore Mining Company that operates mines in Western Australia s Pilbara region This company ho
63. uct transfer conveyors Oversized middlings and fines respectively DOL SP202 205 Sump pumps for the scrubbing area DOL CL201 203 The chillers that provided heat exchanges with cold water to control the gear grease temperature The scrubbing section is designed to take off the outer layer of the ore which it achieves with the large scrubbing machines The outer layer is said to have the most impurity which improves the overall grade of the ore 27 Engineering Internship Terry Gittos 11 1 2013 Fig 2 4 2 3 An industrial scrubber similar to the one installed at Cloudbreak mine site 29 As the ore flows through the scrubber as slurry the scrubber is rotated by driving the gears on the side The slurry will roll off the side towards the bottom of the scrubber and in doing so will scratch the ore along the rough surface inside the scrubber Three scrubbers are installed to keep up with the large volume of ore produced at Cloudbreak Waste Tank Fig 2 4 2 4 An overview of the Scrubbing section of the upgraded facility The system does not need to operate all sections at once since they are isolated This helps to continue production when one of the scrubbers is due for maintenance The ore travels from the feed bins to the scrubbers on conveyors and via pumps thereafter The waste ore is shown in red Engineering Internship Terry Gittos 11 1 2013 3 Control Philosophy A clear scope of the
64. ulates the reference navigator when it is open to show the hardware configuration 39 Engineering Internship Terry Gittos 11 1 2013 PLC4303 Fig 4 2 1 The hardware configuration as shown in PLC 4303 This PLC has a Ea Data Watch Lists lt i Diagnostic Logic Blocks e Active Blocks P Inactive Blocks 2 Ethernet Global Data CR Consumed Exchanges CR Produced Exchanges Hardware Configuration fiji Rack 0 1c6sscHso12 power supply redundant power supply CPU module 4 Ethernet modules 2 Profibus modules DeviceNet module and an Ethernet module in slots 0 though 11 respectively Bla Slot O 1C695PSD 140 H Slot 1 1c695PSD 140 H Slot 2 1c695cruU320 Slot 3 Used With Slot 2 H Slot 4 IC6SSETM0O1 H Slot 5 IC695ETM001 H Slot 6 ICESSETM0O1 H Slot 7 IC6SSETM001 H Slot 8 IC695PBM300 H Slot 9 ICES5PBM300 H Slot 10 C693DNM200 H Slot 11 C695ETM001 H Slot 120 This PLC shares many connections with other PLCs through the Ethernet global data EGD exchange This uses an Ethernet protocol that requires each PLC to be assigned an IP address Extra communications modules are included as redundancies 4 3 LADDER LOGIC Ladder Logicis a graphical programming style that is simple It was designed for electricians and is based on the idea of activating a coil at the end of a wire the way a simple circuit operates The left side of the program is always active and coils
65. ut developing engineering skills as well as adding in new industry relevant ones Large engineering projects are an increasing proposition in the modern world These require engineers of all specializations and background to complete FMG Wet Front End is a project that inundated the assigned undergraduate with engineering concepts and methodology Many facets of engineering knowledge were required to complete the FMG Wet Front End project The process control system was specifically contracted to Motherwell automation and this area of work coincided with the undergraduate s area of study The software and hardware used in the project share similar features to those used in the Industrial Computer Systems engineering major All of the necessary academic objectives were met during the course of this project 8 1 ACHIEVEMENTS 8 1 1 Engineering Practice Problems are certain to occur in a large project such as this one Dealing with and managing problems is good engineering practice and should be done with a system or plan In this project a few examples of the problems includes unexpected client requests to change the SCADA screens overtime on allotted tasks such as the FAT and advanced control code required for the scrubber The changes were handled using the versatility of the team Training was quickly supplied to those with lighter workloads and this was enforced with assigned tasks Increasing the flexibility of the workforce kept the ef
66. w the user access to all necessary information This can be seen below in figure 4 1 1 12035_PLC4303 Proficy Machine Edition infoViewer VE WS Est sem Bora RA Zant Target veier Toc window Ges DRAGS EC BD Hs I LA Name DITESSI LO Descapton Template Pte Level Taremter VegaP ds Man de Logic Developer PLC Logic Developer PC View Lock Settings cem MG Come Profibus Templates Block PEDey_DT_SISTE Motion Representation PBDev DT SISTEC 55200 Linked LD Block mmer 1 Block i on LD Blac inked tothe Tasichesi is an instance of an fubact that exists in the Teolehest Apart from gostem vanabier bles and universa ber the LO linked block are elements of x EER Bais A rer Messages Fest References Compare Te Fig 4 1 1 An overview of the main software screen The main screen has a number of panels that the user must be familiar with in order to program These include 38 Engineering Internship Terry Gittos 11 1 2013 e Reference Navigator on the left can choose the display in the centre panel e Tool bars across the top are useful to create ladder logic e Companion is the bottom left panel and shows useful information about the currently selected item e Feedback Zone on the bottom right gives information regarding ladder code errors server information etc e Inspector shown on the left in grey gives detaile
67. w to test the objects in this project The objects must then be listed according to this template and filled in Objects are also divided into first section of the plant and then class 42 Engineering Internship Terry Gittos 11 1 2013 Document Map v x 5 1 4 Interface Checks PID Description 5 Device Tests 5 1 Scrubber 1 SB214 5 1 1 DOL PU301 PU309 HE201 HE206 5 1 2 VSD CV214 BF214 SB214 PU224 On Off Valve SV6101 SV6149 SV6154 E 5 1 4 Control Valve TCV6148 TCV6152 4 1 Interface Checks Gearbox Lubs ES ie Gearbox Lubi ae Gearbox Lubi Gearbox Lubs gt ia k 5 1 5 1 4 2 Code Checks 5 1 4 3 Control 5 1 4 4 Auto Control 5 1 5 Analogues and PIDs 5 2 Scrubber 2 58215 5 2 1 DOL PU311 PU319 HE207 HE212 1 1 Interface Checks 1 2 Code Checks 1 3 Mode Selection 1 4 Permissives 1 5 Warnings 1 6 Inhibit Interlocks Inhibint 1 7 Process Interlocks ProcInt 1 8 Protection Interlocks ProtInt 1 9 Safety Interlocks SafiInt 1 10 Drive Control 1 11 Run Hours 1 12 Speed Setpoint 5 2 1 VSD CV215 BF215 SB215 PU225 1 1 Interface Checks 1 2 Code Checks 1 3 Mode Selection L 1 Pinion Bearir Pinion Bearir est Engineer Pinion Bearir Pinion Bearir mmmmmm mm D A in NNNNNNNNNNNN 4 Permissives Permint 5 Warnings Warn 1 6 Inhibit Interlocks InhibInt Fig 4 4 1 A FAT document map 5 2 5 2 5 2 5 2 5 2 5 2 P12035 11002 Version 0 05
68. yclone feed tank Digital Valves Twenty valves that aid in controlling the pumps and flow of the slurry in module 4 They include eight gland water valves four suction valves four cyclone feed valves and four drain valves Control Valves 6604 6636 39 The cyclone feed tank process water control valve The classifier teeter water control valves 23 Engineering Internship Terry Gittos 11 1 2013 Classifiers 237 and 238 The classifiers for module 4 Pump 281 The spiral feed pump Pumps 282 283 and 238 The concentrate feed pump spiral tails pump and dewatering screen underpan pump Control Valves 6635 6665 6667 and 6668 The spiral process water and dewatering screen process water control valves Thickener 2 An additional waste treatment thickener added to the process Pumps 259 260 289 290 and 296 The pumps used in the thickener process Digital Valves 6701 6703 6731 42 6739 and 6740 The valves used for the thickener Control Valve 6706 The flocculant dilution control valve Pumps 291 295 The gland water pumps and tailings disposal pumps responsible for transporting the post thickened waste to the tailings dam Sump Pumps 243 247 and 280 Thickener sump pumps Tailings sump pump Transfer line sump pumps Process water area sump pump Pumps 015 017 023 256 298 299 and 101C The pumps require for the new water services area Digital Valves 675

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