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MINING USER CONFERENCE, MAY 3-5, 2017
Vale Itabira CaseOperating and maintaining digital substations based on IEC 61850
Leandro Monaco, Global Product Manager Operations & Electrical Control – System 800xA
Vale – Company Overview
What is IEC 61850?
SAS Vale Itabira overview
How does Vale Itabira SAS allows reduce Operational Expenditures (OPEX)?
Protection and zone selectivity study
Troubleshooting and root cause analysis
Remote operation and monitoring
Additional features that ensure reduced OPEX and ROI
Benefits
May 3-5, 2017 Mining User Conference 2017, StockholmSlide 2
Agenda of presentation
Vale is a private-sector, publically traded company, headquartered in Brazil and present in around 30 countries
Vale – Company overview
Mining User Conference 2017, StockholmSlide 3May 3-5, 2017
Created by the Brazilian federal government on June 1st 1942, with its operations restricted to the state of Minas Gerais.
In its first year, it produced 40,000 tons of iron ore, the same amount it now ships out per hour.
Privatized on May 6th 1997.
Global standard for electrical substation automation and power distribution systems
What is IEC 61850?
May 8, 2017 Slide 4
Interoperability
– Communication for protection & control between IEDs from different vendors
Freedom of configuration
– The ability of each vendor to use different methods in the internal programming of the IEDs, as long as it obeys the goal of interoperability
Long-term stability
– Ability of communication protocols to remain updated in front of technological advances
Based on 3 goals
Substation Automation System in numbers
SAS Vale Itabira overview
May 8, 2017 Slide 5
452 IED’s
21 Substations
– 02 Primary Substations of 230kV
– 02 Substations of 69kV
– 17 Substations of 13.8kV
25 Servers4.806 Tags
26 Workstations
155 Users
21 HMI Panel
First project delivered in 2010
3 Concentration Plants
61850
Vale Itabira SAS Case Study
How does Vale Itabira SAS allows reduce Operational Expenditures?
May 8, 2017 Slide 6
IEC61850 Benefits Vale Itabira cases
Remote Problem Solving
Faster Troubleshooting
Safety for Staff
Optimized Systems
Connect substations
Less maintenance Costs
Energy efficiency & asset optimization
Information readily available
Reduces different technologies
Protection and zone selectivity study
Troubleshooting and root cause analysis
Remote operation and monitoring
How long and which activities would be required?
Protection and zone selectivity study
Mining User Conference 2017Slide 7
Electrical team only goes to substation when needed
Protection and zone selectivity study
May 8, 2017 Slide 8
Logic and parameterization a right-click away, saving time from maintenance team
Protection and zone selectivity study
Mining User Conference 2017Slide 9
Average time for surveying the protection parameters of the 18 IEDs into 2 substations
Protection and zone selectivity study
Mining User Conference 2017Slide 10
Total time for 2 substations and 18 IEDs: 52 min
Start time
End time
Description
10:00 10:01 Communicate with machine 10.16.4.156 and enter access password
10:01 10:05 Opening PCM600 software within environment 10.16.4.156
10:05 10:07 Open the Substation Archive Base SE1215CN01
10:07 10:15 Communicate with relay UY1215CN501, choose the directory and save the settings
10:15 10:21 Time spent with directory difficulty (required to archive settings)
10:22 10:32 Communicate with relay UY1215CN502 to UY1215CN06, enter password and save settings
10:32 10:33 Close substation file SE1215CN01
10:33 10:34 Open the Substation Archive Base SE1475CN01
10:34 10:50 Communicate with relays UY1475CN501 to UY1475CN512 and save to mapped directory
10:51 10:52 Close Machine 10.16.4.156
Risks inherent to the displacement (approx. 6 km round trip)
Exposure to the high voltage in substations (up to 13.8kV)
Need to go up and down stairs
Risk and activities eliminated
Protection and zone selectivity study
Mining User Conference 2017Slide 11
No need to use of helmet, glasses, protection clothes
No need to carry equipment such as laptops and network cables
Fill in risk assessment form
Eliminated Risks Eliminated Activities
Overview from the entire electrical system in the control room
Troubleshooting and root cause analysis
Mining User Conference 2017Slide 12
Same information locally and remotely allowing faster and safer troubleshooting
Troubleshooting and root cause analysis
Mining User Conference 2017Slide 13
x
61850
System overview Remote information about interlocks and protection
Same information locally and remotely allowing faster and safer troubleshooting
Troubleshooting and root cause analysis
Mining User Conference 2017Slide 14
Instant messages for every operation in power system Alarm & Event lists with time stamps from IEDs
Automatic report generation
Troubleshooting and root cause analysis
Mining User Conference 2017Slide 15
Troubleshooting, root cause analysis and correction at the same day
How to make sure that the users have the right knowledge?
Remote operation and monitoring
Mining User Conference 2017Slide 16
Avoid operation mistakes and leverage team knowledge even with low frequency of use
Remote operation and monitoring
Mining User Conference 2017Slide 17
Control, supervision, protection and measurement
Remote operation and monitoring
Mining User Conference 2017Slide 18
Internal trainings for electrical maintenance and operation teams
Reduced the “fear of the unknown” and potentialized the benefits
Mining User Conference 2017Slide 19
Information integration to ensure reduced OPEX and ROI
CCTV
Historian
Condition Monitoring
Energy Management
Additional features
Mining User Conference 2017Slide 20
Information integration to ensure reduced OPEX and ROI
CCTV
Historian
Condition Monitoring
Energy Management
Additional features
Mining User Conference 2017Slide 21
Information integration to ensure reduced OPEX and ROI
CCTV
Historian
Condition Monitoring
Energy Management
Additional features
Mining User Conference 2017Slide 22
Information integration to ensure reduced OPEX and ROI
CCTV
Historian
Condition Monitoring
Energy Management
Additional features
Safer data collection
– Electrical data in real time and from a safe location
Productivity
– Analyze each set of equipment: consumption per ton of ore
Increased operating time
– Shorter maintenance shutdowns, reducing the risk of human failure
Cheaper and safer
– Savings of 600 km of electric cables
Simplified operation
– Change protection parameters via software and automatic system fault reports
Operating and maintaining digital substations based on IEC 61850
Benefits
Mining User Conference 2017Slide 23
IEC61850 is present in almost every Vale plant in Brazil!
Source: vale.com/brasil/EN/aboutvale/news/Pages/projeto-s11d-utiliza-tecnologia-inovadora-automacao-subestacoes-eletricas.aspx
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