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Directions of Automation Development in Polish Mining Companies
IFAC Workshop Automation in MMM Industry
20-22 September 2006
Cracow, Poland
DIRECTIONS OF AUTOMATION DEVELOPMENT IN POLISH MINING COMPANIES
Stefan Kolon, Zenon Mrozek CARBOAUTOMATYKA SA, Tychy, Poland
In recent years we can observe changes in Polish hard coal mming companies, first of all, dictated by the demand to maintain competitiveness of coal on Polish and global markets of ores. This thesis requires searching for cutting the costs on each and all levels, also by means of transformation of property and by organizational changes, in order to create effective management and activity structures and to establish technologies of exploitation which depend on geological conditions, level of productiveness, and effectiveness in using the existing infractructure of machines and equipment by measn of reducing the standstills caused by breakdowns and operational actions. In order to perform correct economical and financial analyses and make corrections of organizational and technological activities the fundamental formula of efficiency evaluation of the perfonned actions become the principles of economic controlling of technological processes, which refer the costs to the places in which they arc generated,. These problems howevcr arc beyond the frames of this article, which concentrates on the efforts to determine the clemcnts of automatics and construction of complcte automation systems as thc tools supporting the managcment of contemporary mining company in conditions of free market. Wc arc at the same time aware of gradual technical changes needed in the existing plants, without imposing of additional standstills or temporary decrease of safety level. CARBOAUTOMATYKA SA contributes to the services in mining industry in the field of power supply, control and visualisation of underground and surface mming machinery and also is the manufacturer of gas measuring detectors and other elements of the systems automation. Thirty years of experience gained from rendering seFYices for mining companies , manufacturers of mmmg machinery, cooperation with scientific institutions, allow us to define expectations of our customers and offer equipment, systems and services according to their needs and also determine and forecast the development directions of this sector. Division of a mining plant to the underground headings and open casts is obvious in compliance of mandatory directives, standards and rules regulating the procedures of activity and consequently, in scope of design of machines, devices and systems. Another division emerges, which includes mining headings, consisting in the separation of safety systems from the control systems and from management of production processes, however both systems cooperate, interpenetrating on many levels.
Mining headings Safety and environment conditions management systems Current conditions of exploitation produce the need for new approach to secure safety of working mining crews, shaping of the environment working conditions in order to create the grounds for effective 76
utilisation of working time and technical infrastructure.
Expectations concerning the range of monitoring and interactions: Automatic maintenance-free monitoring of the environment and atmosphere parameters • Automatic positioning of people and machines in the headings Measurement of physiological and functional parameters of miners Limits of time for people staying in the areas of higher risk Air conditioning of headings and individual air conditioning Regulation of ventilation parameters, automatic stoppings controlled locally as well as from the surface Automatic maintenance-free monitoring of a deposit demethanisation • A utomatic monitoring of rock mass stresses (geotomography ) Visual and thermovisual supervision and supervision of mining areas • Wireless individual communication, with possibility of automatieal sending of messages. Automatic control of backlit banners and warning messages of variable loudness level. Ability to simulate hazards Existing of the behaviour procedures base in case of hazards Archiving of data and events, study of cases, approximation of result
Development of science and technological novelties will allow in near future to elaborate new elements of safety systems, which will be based on: • Application of RFID technology Radio Frequency Identification) • Application of PDA readers ( Personal Digital Assistant) • Application of the SAM family atmosphere detectors (Sensor Array Measurement) • Application of SSN ( Smart Sensor Networks) and MEMS ( Micro Electro - Mechanical System) technologies Functioning in real time, application of the latest achievements of telecommunication and data processing technologies
Belt conveyor scales
Monitoring of the quantities and monitoring of the media control ( energy supply, compressed air, water) Ability for remote visual supervision Multilevelled access to the system via local, group and surface management centres Image (lankowice underground dispatch office)
It is worth saying that currently used measuring sensors and detectors designed on the basis of outdated technologies have already exploited their abilities and no longer meet the requirements In constructing of new measuring systems .
Technological processes managing systems
We can already now observc the intensified needs in scope of: • Ability for remote control of machines, devices and objects in the mining headings, such as : longwall complexes, haulage of excavated material by belt conveyors, water pumping stations, loading devices, power networks and power supply systems Stepless regulation of rotational speed of driving machines together with monitoring of load torque of excavating machines and transporting equipment
Dispatcher KWK Jankowice
Remote diagnostic testing of devices and machines by the producer's service after obtaining respective authorization from the user Software support in managing the processes, with the function for analysing of the parameters and anticipating of breakdowns. Compatibility of devices and systems, Data bases of spare parts and subassemblies, along with logistics of deliveries Data bases of dates of periodical inspections and repairs Archiving of measured data and events
I'
Voltage frequelllY collverter
•
Expectations defined in that way or even at the present moment, the needs of Polish contemporary and future mining direct the application of: Wireless two-way data transmission of large throughput Local and plant controllers of big data processing power, with the possibility of analogue and digital inputs New generation of measuring detectors based on the afore mentioned latest technologies such as SSN (Smart Sensor Networks ) and MEMS (Micro Elektro - Mechanical System)
Continuous monitoring of the machines and devices working parameters Positioning of equipment in the mining headings Monitoring of excavated material parameters in the longwall complex haulage (quantity and quality measurement)
77
•
Functioning of systems in real time Typification of equipment, networks software .
Devices with controlled output by applying of inverters Continuous measurements of physical and technological quantities of the stations Software connection with the system of monitoring of the demethaning pipelines in the mining headings Equipment for utilization of obtained gas, consideing the ecological and economical conditions, in separated co-generating systems
and
Another problem, however important and deciding of correct functioning of the safety management systems and technological processes management systems is their reliability and interoperability on each and every level of the system structure. Only the applying of up-to-dated technologies from the fields of electronics, metrology, automation , mechanical engineering, elements of higher functioning reliability can provide expected and desired level of reliability of the systems with consideration of geological and exploitational hazards .
~::1';
~~~~24=~
Surface level of mining plants On the surface area of the mining plant important objects deciding on the level of safety and technological process efficiency are localised . Requirements relating to their functioning and rcliability have been precised, and modernization works already started .
-.---
,,. .. ~ - .
, . i i _.
"' "4"
,
.
Processing plants, dispatch, loading: The object described above, in its final technological stage, prepares the product with defined physical and chemical parameters for despatch, thus the importance and functioning of the plant in the economical dimension is essential and combined with the processes management system and also with economical and financial software . " CARBOAUTOMATYKA" SA designed and implemented the system named SOLARIS for management of the processing plant. The system consists of the following interconnected managing programs:
In the overwh elming majority of cases we are discussing the objects built tens of years ago , and con sequently, the range of modernization is limited by the building and machinery infrastructure, which are the obstacles to free approach to the technical solutions . Fan stations of the main ventilation system, alr compressor stations, winding gear: Scope of necessary modernizations means the equipping of mines with: Continuous measurements of physical quantities • The plant visualisation and diagnostics microprocessor control systems Automatic control systems for capacity and velocity values
" Solaria" is the complete system of interoperational solutions of automatization for the Mechanical Processing works. Interconnected objects make the harmonious whole , characterized with the unreached so far abilities for management of the production .
Helios - Centre of the system - this is a compendium of knowledge worked out from information incoming from other plants. Enables to generate various reports and compilations Merkury - Preparation of energetic mixtures Wen us - Automatic loading of coal Terra - Supervision over general cargo scales Luna - Automatic loading of general cargo Mars - Balancing of transport and storage of coal Staturn - visualisation of processing plant operation Uran - stabilization of dense medium
Limiting of driving motors starting parameters Automatic connections between software and safety and technological systems
Structure of a master system In this article we have tried to define the individual systems for management of the safety, technological processes both underground and on the surface of a mining plant. It is necessary to design the data
Surface demethanizing stations deciding on the rate of degassing of coal deposits, equipped with :
78
processing master system combining all the specified systems in its surface fonn into a single system. The basic objective of such defined master system will be the controlling as well as maintaining of high level of redundancy of the sub-systems functioning of safety, technological processes as well as communication systems. Also all databases would be defined on the level of the master system, supporting the action In case of occuring of the hazards. We can also see the necessity of the coherency between the discussed master system and the data processing, organizational, economical and financial programes. Making available of the data for the superior organizations also becomes important; in this case the owners supervision and the state mining supervising authorities. Such a configuration and multitude of functions enforees the determined high requirements for the hardware and also the requirements relating to expanded and reliable telecommunication and data processing system with using of the alternative routes of daia transmission.
Summary Expectations presented in this article as well as the development directions in some cases already being implemented. This is why, while building the elements of the discussed systems we should take into consideration the whole complex structure together with the master system. Building of systems will be done step by step and will be perfonned in the existing mining plants, what for the contractors of the investments has always been the difficulty. On higher levels of the systems functioning we will have to combine different standards and data processing programs. In the presented problematics of objectives, which appear to be made in the Polish mining industry, and not only, "CARBOAUTOMATYKA"SA is the enterprise which can match the posed expectations in a complex way, and on the highest level of quality of rendered services.
79
20-22 September 2006
Cracow, Poland
DIRECTIONS OF AUTOMATION DEVELOPMENT IN POLISH MINING COMPANIES
Stefan Kolon, Zenon Mrozek CARBOAUTOMATYKA SA, Tychy, Poland
In recent years we can observe changes in Polish hard coal mming companies, first of all, dictated by the demand to maintain competitiveness of coal on Polish and global markets of ores. This thesis requires searching for cutting the costs on each and all levels, also by means of transformation of property and by organizational changes, in order to create effective management and activity structures and to establish technologies of exploitation which depend on geological conditions, level of productiveness, and effectiveness in using the existing infractructure of machines and equipment by measn of reducing the standstills caused by breakdowns and operational actions. In order to perform correct economical and financial analyses and make corrections of organizational and technological activities the fundamental formula of efficiency evaluation of the perfonned actions become the principles of economic controlling of technological processes, which refer the costs to the places in which they arc generated,. These problems howevcr arc beyond the frames of this article, which concentrates on the efforts to determine the clemcnts of automatics and construction of complcte automation systems as thc tools supporting the managcment of contemporary mining company in conditions of free market. Wc arc at the same time aware of gradual technical changes needed in the existing plants, without imposing of additional standstills or temporary decrease of safety level. CARBOAUTOMATYKA SA contributes to the services in mining industry in the field of power supply, control and visualisation of underground and surface mming machinery and also is the manufacturer of gas measuring detectors and other elements of the systems automation. Thirty years of experience gained from rendering seFYices for mining companies , manufacturers of mmmg machinery, cooperation with scientific institutions, allow us to define expectations of our customers and offer equipment, systems and services according to their needs and also determine and forecast the development directions of this sector. Division of a mining plant to the underground headings and open casts is obvious in compliance of mandatory directives, standards and rules regulating the procedures of activity and consequently, in scope of design of machines, devices and systems. Another division emerges, which includes mining headings, consisting in the separation of safety systems from the control systems and from management of production processes, however both systems cooperate, interpenetrating on many levels.
Mining headings Safety and environment conditions management systems Current conditions of exploitation produce the need for new approach to secure safety of working mining crews, shaping of the environment working conditions in order to create the grounds for effective 76
utilisation of working time and technical infrastructure.
Expectations concerning the range of monitoring and interactions: Automatic maintenance-free monitoring of the environment and atmosphere parameters • Automatic positioning of people and machines in the headings Measurement of physiological and functional parameters of miners Limits of time for people staying in the areas of higher risk Air conditioning of headings and individual air conditioning Regulation of ventilation parameters, automatic stoppings controlled locally as well as from the surface Automatic maintenance-free monitoring of a deposit demethanisation • A utomatic monitoring of rock mass stresses (geotomography ) Visual and thermovisual supervision and supervision of mining areas • Wireless individual communication, with possibility of automatieal sending of messages. Automatic control of backlit banners and warning messages of variable loudness level. Ability to simulate hazards Existing of the behaviour procedures base in case of hazards Archiving of data and events, study of cases, approximation of result
Development of science and technological novelties will allow in near future to elaborate new elements of safety systems, which will be based on: • Application of RFID technology Radio Frequency Identification) • Application of PDA readers ( Personal Digital Assistant) • Application of the SAM family atmosphere detectors (Sensor Array Measurement) • Application of SSN ( Smart Sensor Networks) and MEMS ( Micro Electro - Mechanical System) technologies Functioning in real time, application of the latest achievements of telecommunication and data processing technologies
Belt conveyor scales
Monitoring of the quantities and monitoring of the media control ( energy supply, compressed air, water) Ability for remote visual supervision Multilevelled access to the system via local, group and surface management centres Image (lankowice underground dispatch office)
It is worth saying that currently used measuring sensors and detectors designed on the basis of outdated technologies have already exploited their abilities and no longer meet the requirements In constructing of new measuring systems .
Technological processes managing systems
We can already now observc the intensified needs in scope of: • Ability for remote control of machines, devices and objects in the mining headings, such as : longwall complexes, haulage of excavated material by belt conveyors, water pumping stations, loading devices, power networks and power supply systems Stepless regulation of rotational speed of driving machines together with monitoring of load torque of excavating machines and transporting equipment
Dispatcher KWK Jankowice
Remote diagnostic testing of devices and machines by the producer's service after obtaining respective authorization from the user Software support in managing the processes, with the function for analysing of the parameters and anticipating of breakdowns. Compatibility of devices and systems, Data bases of spare parts and subassemblies, along with logistics of deliveries Data bases of dates of periodical inspections and repairs Archiving of measured data and events
I'
Voltage frequelllY collverter
•
Expectations defined in that way or even at the present moment, the needs of Polish contemporary and future mining direct the application of: Wireless two-way data transmission of large throughput Local and plant controllers of big data processing power, with the possibility of analogue and digital inputs New generation of measuring detectors based on the afore mentioned latest technologies such as SSN (Smart Sensor Networks ) and MEMS (Micro Elektro - Mechanical System)
Continuous monitoring of the machines and devices working parameters Positioning of equipment in the mining headings Monitoring of excavated material parameters in the longwall complex haulage (quantity and quality measurement)
77
•
Functioning of systems in real time Typification of equipment, networks software .
Devices with controlled output by applying of inverters Continuous measurements of physical and technological quantities of the stations Software connection with the system of monitoring of the demethaning pipelines in the mining headings Equipment for utilization of obtained gas, consideing the ecological and economical conditions, in separated co-generating systems
and
Another problem, however important and deciding of correct functioning of the safety management systems and technological processes management systems is their reliability and interoperability on each and every level of the system structure. Only the applying of up-to-dated technologies from the fields of electronics, metrology, automation , mechanical engineering, elements of higher functioning reliability can provide expected and desired level of reliability of the systems with consideration of geological and exploitational hazards .
~::1';
~~~~24=~
Surface level of mining plants On the surface area of the mining plant important objects deciding on the level of safety and technological process efficiency are localised . Requirements relating to their functioning and rcliability have been precised, and modernization works already started .
-.---
,,. .. ~ - .
, . i i _.
"' "4"
,
.
Processing plants, dispatch, loading: The object described above, in its final technological stage, prepares the product with defined physical and chemical parameters for despatch, thus the importance and functioning of the plant in the economical dimension is essential and combined with the processes management system and also with economical and financial software . " CARBOAUTOMATYKA" SA designed and implemented the system named SOLARIS for management of the processing plant. The system consists of the following interconnected managing programs:
In the overwh elming majority of cases we are discussing the objects built tens of years ago , and con sequently, the range of modernization is limited by the building and machinery infrastructure, which are the obstacles to free approach to the technical solutions . Fan stations of the main ventilation system, alr compressor stations, winding gear: Scope of necessary modernizations means the equipping of mines with: Continuous measurements of physical quantities • The plant visualisation and diagnostics microprocessor control systems Automatic control systems for capacity and velocity values
" Solaria" is the complete system of interoperational solutions of automatization for the Mechanical Processing works. Interconnected objects make the harmonious whole , characterized with the unreached so far abilities for management of the production .
Helios - Centre of the system - this is a compendium of knowledge worked out from information incoming from other plants. Enables to generate various reports and compilations Merkury - Preparation of energetic mixtures Wen us - Automatic loading of coal Terra - Supervision over general cargo scales Luna - Automatic loading of general cargo Mars - Balancing of transport and storage of coal Staturn - visualisation of processing plant operation Uran - stabilization of dense medium
Limiting of driving motors starting parameters Automatic connections between software and safety and technological systems
Structure of a master system In this article we have tried to define the individual systems for management of the safety, technological processes both underground and on the surface of a mining plant. It is necessary to design the data
Surface demethanizing stations deciding on the rate of degassing of coal deposits, equipped with :
78
processing master system combining all the specified systems in its surface fonn into a single system. The basic objective of such defined master system will be the controlling as well as maintaining of high level of redundancy of the sub-systems functioning of safety, technological processes as well as communication systems. Also all databases would be defined on the level of the master system, supporting the action In case of occuring of the hazards. We can also see the necessity of the coherency between the discussed master system and the data processing, organizational, economical and financial programes. Making available of the data for the superior organizations also becomes important; in this case the owners supervision and the state mining supervising authorities. Such a configuration and multitude of functions enforees the determined high requirements for the hardware and also the requirements relating to expanded and reliable telecommunication and data processing system with using of the alternative routes of daia transmission.
Summary Expectations presented in this article as well as the development directions in some cases already being implemented. This is why, while building the elements of the discussed systems we should take into consideration the whole complex structure together with the master system. Building of systems will be done step by step and will be perfonned in the existing mining plants, what for the contractors of the investments has always been the difficulty. On higher levels of the systems functioning we will have to combine different standards and data processing programs. In the presented problematics of objectives, which appear to be made in the Polish mining industry, and not only, "CARBOAUTOMATYKA"SA is the enterprise which can match the posed expectations in a complex way, and on the highest level of quality of rendered services.
79