Foundation Coal 4100XPB, Shovel 10 P&H Centurion 750 Control … … · Foundation Coal 4100XPB,...
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Foundation Coal 4100XPB, Shovel 10 P&H Centurion 750 Control System Upgrade Presented by: P&H MinePro Services Gillette, Wyoming November 17, 2006
Transcript of Foundation Coal 4100XPB, Shovel 10 P&H Centurion 750 Control … … · Foundation Coal 4100XPB,...
Foundation Coal 4100XPB, Shovel 10P&H Centurion 750
Control System Upgrade
Presented by:P&H MinePro Services
Gillette, WyomingNovember 17, 2006
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Overview Overview • Upgrade Packages Available• Centurion / Upgrade Benefits• Machines Upgraded to Date • Foundation Coal, Centurion 750 Background• Upgrade Goals• Installation• Results• Questions
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Centurion Upgrade Options
• Centurion – Complete System Upgrade
• Centurion 750– Controller and I/O upgrade to digital system
• Centurion 500– Controller upgrade for digital systems
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Centurion “Full” Upgrade
• Analog or Digital system replacement• Complete System Upgrade
– Touch Screens– Controller– Smart I/O– Drives– Complete control cabinet
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Centurion UpgradeAnalog Layout Centurion Layout
GUI
GUI
AC 800
DrivesSmartI/O
PanelView PLC
I/O AnalogDrives
PMD
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Centurion 750
• Digital system control upgrade– Touch Screens– Controller– Smart I/O
• Uses existing drives and control cabinet• System converted to Centurion
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Centurion 750DDC Layout 750 Layout
GUI
OAP
GUI
PLC
RemI/O AC 80
Drives
GUI
GUI
AC 800
DrivesSmartI/O
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Centurion 500
• Digital system control upgrade– Touch Screens– Controller
• Uses existing drives, I/O, and control cabinet• Cost effective upgrade with minimal investment
of resources
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Centurion 500DDC Layout 500 Layout
GUI
OAP
GUI
PLC
RemI/O AC 80
Drives
GUI
GUI
AC 800
PLC Drives
RemI/O
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Centurion Based Upgrades
• Remote Communications• Payload Measurement• Automated Control
Remote Communications• ShoveLink
– Remote shovel monitoring– Faults, temps, recordings– Data via OPC
• ShoveLink II– Fleet management– Web based – SQL Server 2005– New diagnostic tools– Supporting documentation
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Payload Measurement
• Payload and Payload Plus– Accuracy of 2% (error)– Precision of 4% (repeatability)– Calibration is very simple
• Reporting software– SQL Server 2005– Remote downloads
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Automated Control• OptiDig II• ABSS• 3D Track Protection
– Avoids collisions– Geometric model of
shovel– Predicts position/makes
corrections– Tested and running on
2100BLE and 4100A
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Upgrade Benefits Upgrade Benefits PerformancePerformance
Reduced Propel transfer timeReduced cycle times from Crowd extended speed rangeCoordinated motion speedsOpti-Dig IIIntegrated control of machine and driveNext generation automation options
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Upgrade Benefits Upgrade Benefits DiagnosticsDiagnostics
High level drive and controller diagnostics from the GUISmart I/O with safer 24V DC control Smart I/O with internal diagnostics and health status from the GUISimple and quick replacement of snap-in Smart I/O modules High bandwidth industry standard Profibus I/O networkImproved noise immunity via fiber optic Profibuscabling
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Upgrade Benefits Upgrade Benefits New FunctionsNew Functions
Optional logarithmic joystick function, allows for smoother operation during small joystick movements.A brake set logic tracks time from brake solenoid “off” to pressure below 5 psi. A warning is logged if the time is greater then 500 ms.Soft shutdown logic added, allows controlled shutdowns of independent motions.Swing impact detection with optional alert sounded when impact is detected.Lube system faults will not trigger a immediate shutdown on the first occurrence; allows the operator to re-set the logic in an attempt to free a frozen/ lube line. After three failures or 15 minutes of non-lube operation, will cause trip.RPC bank hysteresis adjusted to allow for more aggressive switching of banks.
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Centurion Shovels to Date Centurion Shovels to Date • Upgrades
20 – 4100 / 4100A / 4100XPB17 - 2800XPA / 2800XPB 2 - 2300XPLR
• New shovel sales with Centurion as OE38 – 4100C / 4100XPC / 4100BOSS22 – 2800XPB 2 - 2300XPC
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FoundationFoundation--Centurion 750 Centurion 750 Background Background
4100XPB, SN ES41111, commissioned in October 2001
100,000 hour MARC Agreement
Centurion installed at approximately 33,000 hours started on June 26, 2006
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Manpower/TimingManpower/TimingStarted outage June 26, 2006, duration of 11 daysRetrofit was performed in conjunction with a major mechanical outageCenturion can be installed in 8 daysInstallation of hardware took 5 days
3 men on days3 men on nights
Testing and commissioning took 3 days2 men on days
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Upgrade Goals/Upgrade Goals/KPIKPI’’ss• Demonstrate an improvement of .5 seconds in the dig cycle• Demonstrate an improvement of 3 seconds (+/- .25 seconds) in propel
transfer time each direction (6 seconds total)• System-wide minimum availability is to be 88% for all hours of operation
during the trial period• All systems must pass an MSHA safety inspection for safe and efficient
operation• All electrical and control systems must demonstrate full integration and meet
all electrical codes • All components and equipment must be designed and installed for
reasonable ease of access and maintenance
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Project InstallProject Install
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Operator’s Cab
Hall effectErgonomicLogarithmic
New GUI’sIndependentNew screens
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Control CabinetAB SLCABB AC 80
ABB AC 800Siemens Smart I/O
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Control CabinetABB DrivesOld GUI
Fiber Optic Branching UnitFilter, Power Supply, Resolver Module
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Auxiliary Cabinet Old Flex I/O Siemens Smart I/O
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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RPC Control
Old Flex I/OSelf Contained RPC ControlPLC, Smart I/O, kVAR xducer, firing board, sync xfmr, filter, power supply
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Hoist I/OHoist I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
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Transfer Cabinet
Flex I/OSmart I/OFilter & power supply
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Converter Cabinet
Old Flex I/OSmart I/OFilter & power supply
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Hoist I/O Drop
• Added for more localized control and cabling
• Room for expansion for RTD’s
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Lube RoomSmart I/OFilter & power supplyOld Flex I/O
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Front Machine House I/O Drop
• Added for more localized control and cabling
• Old system split this control between the lube room and right hand room
• Room for expansion
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Lower Lower Works I/O Works I/O (located on (located on the lower the lower works)works)
Lube Room I/OLube Room I/OTransfer Transfer Cabinet I/OCabinet I/O
Converter I/OConverter I/O
RPC I/ORPC I/O
Auxiliary I/OAuxiliary I/O
Front Machine Front Machine House Wall I/OHouse Wall I/O Operator Operator
Cab Cab Touch Touch ScreenScreenOperator Operator
Cab I/OCab I/OControl Control Cabinet I/O Cabinet I/O and and ControllerController
Control Control Room Room Touch Touch ScreenScreen
Hoist I/OHoist I/O
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Lower Control Cabinet
Siemens Smart I/OAll new componentsFlex I/O
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New 24vdc ComponentsTypical Brake BoxTransducers & new 24vdc brake solenoids
Solenoid (MAC) Valves24vdc coils
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Results Results Demonstrated an improvement of 0.52 seconds in the dig cycleDemonstrated an improvement of 6.73 seconds improvement in the time it takes to switch from dig to propel and back System-wide availability was 93% for all hours of operation during the trial period and has been 93-94% post commissioningAll systems passed MSHA regulations for safe and efficient operationAll electrical and control systems fully integrated and met all electrical codes All components and equipment were designed and installed for reasonable ease of access and maintenance
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Questions?
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Vision StatementVision Statement
Our vision is to be the surface mining industry’s preferred partner -- continuously
striving to provide reliable, innovative products and services that reduce our
customers’ costs
