Welkom Industrial Controls

September 2011 System Integration & Control Systems Design

Keeping maintenance to a minimum with integrated solutions.

Welkom Industrial Controls (WIC) recently upgraded the scada system of a major mining house from Wonderware’s Intouch to the ArchestrA System Platform. The drive behind this was the size that the shaft had grown to with regard to the equipment to be monitored and controlled.

“Over the past five years WIC has been involved in the upgrade and automation of two surface compressors, 20 underground pumps, two surface fans and the monitoring for all the underground MV switchgear,” says WIC’s Llewellyn Coveney-Winter. “This was all automated using Schneider Electrics’ Quantum and Momentum PLC solutions.

“The scada’s historian is logging approximately 50 000 I/O points with zero failures. This ensures accurate, up to date and efficient data at the operator’s fingertips. The system has been deployed over six high-end Dell servers with two application object servers in place for full redundancy.

“A standalone Galaxy repository and development machine, a historian to log historical data, a Wonderware Information Server and a view node complete the system. The two application object servers afford the client a seamless transfer if there is a hardware failure on one of the servers.

The Wonderware information server gives the mine’s managers access to critical reports and graphical overviews of the equipment via a web browser. This assists them in a hands-on way to manage the mine better. Custom reports can be set up to run at predetermined times and published to the information server, making information readily available and meaning engineers no longer have to wait for reports.

“As ArchestrA is an object-based system it is easy for the client to do modifications and upgrades on their own. We tried to simplify the complex system requirements, especially the graphical representation, in order to make it as user friendly as possible. Our aim here is to improve efficiency in the control rooms as well as in troubleshooting,” explains Coveney-Winter.

He adds that one of the main advantages of the upgrade is that a single application is used for the entire system that allows for substantial expansion when required. “The interface between the scada and PLC systems has proven itself time and time again. This is our preferred solution combination whether it is in a plant, shaft or process environment.”

The Schneider Quantum and Momentum PLCs used to automate the equipment are ideal for the application as they are especially robust for the underground mining environment. Reliability is critical in the mine, since it is difficult to tackle underground breakdowns. In addition, with the drive towards energy conservation, unexpected breakdowns at peak energy times can lead to energy wastages.

A standard, including the use of only one software type, has been maintained on site in order to limit stock holding and ensure rapid maintenance and support. All design and engineering as well as the manufacturing and installation of the hardware component was undertaken in-house by WIC. “This allows for a better understanding of the system and makes the integration of the components simpler,” says Coveney-Winter. “This is the fifth ArchestrA system implemented by Welkom Industrial Controls for a major mining house.”

For more information contact Llewellyn Coveney-Winter, Welkom Industrial Controls, +27 (0)57 357 5724, [email protected], www.wic.co.za

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