4
INTERNAL
CONTROL HIERARCHY
Base Layer Control – Interlocks, sequences and regulatory control
Base Layer Control – Intervention control
Advanced – Fuzzy logic rule-based
control
Advanced – Model
Predictive Control
Plant Wide
Optimization
APET
PLC
Complexity
Programmable
Logic
Controller
Advanced
Processing
Equipment
Technology?
6
INTERNAL
PROCESS CONTROL OBJECTIVES
1. Control Objectives
– Maintain all controlled variables (CVs) within
limits (feasible soln.)
– Reduce Variation in PV
– Most important,
2. Optimization Objectives
– ONLY applicable to manipulated variables
(MVs)
– Shift the mean
– Only available on MPC algorithms
Control technologies can have up to two objective types, depending of the level of control sophistication.
Control Objective Optimization Objective
Delta
Avg.
Before
Control
Optimisation
Optimization
Objective
–
Process
Limit
PROCESS
VARIABLE
Control
Objective
7
INTERNAL
CONTROL IN ANGLO AMERICAN Layers of Control
Description
E.g. Autonomous Equipment
(Onboard Control)
E.g. Flotation Unit Control
(PLC/SCADA)
E.g. Load out Control
(PLC/SCADA)
Regulatory Control (PID / Sequences / ARC) – Process Ilocks & Alarms – S88, ASM Process
Safety
&
Stability
Level 2 100ms
ICS/S88
Levels
Enterprise Wide Control (ERP) / Optimization (LP Models)Enterprise Wide Control
&
Optimization
Level 5 Days/ weeks/
months
Level 5
Mine Wide Controlling Plant Wide Controller Logistics Controller
Real Time Optimization and Scheduling
MES / MIS & Dynamic Simulation
Optimization
& Scheduling Level 4
30min – 8hrs Level 4
E.g. Dynamic Dispatch
Systems, Drill Positioning
Systems
E.g. Flotation Circuit, Mill
Circuit (Model Predictive
Controllers)
E.g. Pipeline Controller
Soft Sensors & Advanced Control (Fuzzy / MBC / MPC) Unit
Optimization
&
Stability
Level 3 10s-30min
Level 2
Instruments / Devices / Equipment – Interlocks and Alarms – ASM
Mining Processing/Plant Logistics
E.g. Drives / Conveyors /
Float Cell Motor Circuit
Breakers
E.g. Rail CarE.g. OEM protection on trucks
Equipment
Protection
Physical
Process
Level 1 1ms
Level 0
Level 1
Level 0
ISA 95
Levels
9
INTERNAL
ADVANCED LAYER FLOTATION CONTROL Layers of Control
Description
E.g. Autonomous Equipment
(Onboard Control)
E.g. Flotation Unit Control
(PLC/SCADA)
E.g. Load out Control
(PLC/SCADA)
Regulatory Control (PID / Sequences / ARC) – Process Ilocks & Alarms – S88, ASM Process
Safety
&
Stability
Level 2 100ms
ICS/S88
Levels
Enterprise Wide Control (ERP) / Optimization (LP Models)Enterprise Wide Control
&
Optimization
Level 5 Days/ weeks/
months
Level 5
Mine Wide Controlling Plant Wide Controller Logistics Controller
Real Time Optimization and Scheduling
MES / MIS & Dynamic Simulation
Optimization
& Scheduling Level 4
30min – 8hrs Level 4
E.g. Dynamic Dispatch
Systems, Drill Positioning
Systems
E.g. Flotation Circuit, Mill
Circuit (Model Predictive
Controllers)
E.g. Pipeline Controller
Soft Sensors & Advanced Control (Fuzzy / MBC / MPC) Unit
Optimization
&
Stability
Level 3 10s-30min
Level 2
Instruments / Devices / Equipment – Interlocks and Alarms – ASM
Mining Processing/Plant Logistics
E.g. Drives / Conveyors /
Float Cell Motor Circuit
Breakers
E.g. Rail CarE.g. OEM protection on trucks
Equipment
Protection
Physical
Process
Level 1 1ms
Level 0
Level 1
Level 0
ISA 95
Levels
13
INTERNAL
ADVANCED LAYER FLOTATION CONTROL Layers of Control
Description
E.g. Autonomous Equipment
(Onboard Control)
E.g. Flotation Unit Control
(PLC/SCADA)
E.g. Load out Control
(PLC/SCADA)
Regulatory Control (PID / Sequences / ARC) – Process Ilocks & Alarms – S88, ASM Process
Safety
&
Stability
Level 2 100ms
ICS/S88
Levels
Enterprise Wide Control (ERP) / Optimization (LP Models)Enterprise Wide Control
&
Optimization
Level 5 Days/ weeks/
months
Level 5
Mine Wide Controlling Plant Wide Controller Logistics Controller
Real Time Optimization and Scheduling
MES / MIS & Dynamic Simulation
Optimization
& Scheduling Level 4
30min – 8hrs Level 4
E.g. Dynamic Dispatch
Systems, Drill Positioning
Systems
E.g. Flotation Circuit, Mill
Circuit (Model Predictive
Controllers)
E.g. Pipeline Controller
Soft Sensors & Advanced Control (Fuzzy / MBC / MPC) Unit
Optimization
&
Stability
Level 3 10s-30min
Level 2
Instruments / Devices / Equipment – Interlocks and Alarms – ASM
Mining Processing/Plant Logistics
E.g. Drives / Conveyors /
Float Cell Motor Circuit
Breakers
E.g. Rail CarE.g. OEM protection on trucks
Equipment
Protection
Physical
Process
Level 1 1ms
Level 0
Level 1
Level 0
ISA 95
Levels
18INTERNAL
MP CONTROLLER – MOTOTOLO
Uncontrolled mass pull
RD ~ 1.07 kg/ L
Controlled mass pull
RD ~ 1.16 kg/ L
HG conc. flow
MG conc. flow
19INTERNAL
MP CONTROLLER – MNC
Yellow line is either:
Flow rates
Froth depth
We need to ask
(graph is not
labelled, we need
data)
Relative Standard Deviation –
Standard deviation (data
spread with respect to the
mean of a set of values) of
two factors over a range
(readings at different times)
20INTERNAL
GRADE CONTROLLER – AMANDELBULT U2
PGM Lo-Limit
