Energy & Automation, Inc.
MEMSA Annual Meeting
St. Petersburg, FL
September 5, 2002
Walter Koellner
SiRAS & MIDAS
Remote Diagnostics
and More
First AccessDirect Installation:
12/2001
 Boliden
Sweden
Mining Technologies
Energy & Automation, Inc.
Energy & Automation, Inc.
Remote Locations
 Antamina
Peru
Mining Technologies
Energy & Automation, Inc.
Why Remote Diagnostics?
Keep the factory on your machine
 Remote diagnostics let the factory experts help you troubleshoot immediately.
No travel time is required.
On line monitoring
 Find out instantly how the machine operates. Monitor operation from the site
office, the Siemens office, or any Internet connection.
Immediate software updates
 No down time, software can be downloaded and installed while the
machine is operating.
PM aids
 Advanced diagnostic programs can monitor and test not only your electrical but
also your mechanical systems.
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
The philosophy behind SiRAS Remote Diagnostics is MIDAS…
Mining Technologies
SiRAS and MIDAS
Energy & Automation, Inc.
Why MIDAS
Normally measured data is in raw format.
Problems
It is difficult to correlate data with real events.
Data is often incompatible with programs like Microsoft Office, etc.
MIDAS
Presents processed information in a clear, precise manner.
Our
Solution
Custom tailored user interface extract data relevant to special groups.
Seamlessly integrates with Microsoft Office tools.
Leverages expertise from Siemens factory based development and
service personnel.
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
Why MIDAS
Problems
Problems
eliminated
Mining Technologies
SiRAS and MIDAS
Energy & Automation, Inc.
Data size:
For a 24 hours period, 50 Million bytes of Data
are accumulated for a shovel.
This Data encompasses:
 Key production Data
 Complete Machine Health Data
 Key Operations Data
 Power Consumption & Line Monitoring Data
Now let’s take a look at the MIDAS Parts.
Mining Technologies
Energy & Automation, Inc.
Monitoring
M
Monitoring
I
Interaction
D
A
Diagnostics
S
Analysis
 Real time monitoring with data logging
 XY or YT plots to determine machine performance
 Native interface to “Accuweigh”
Mining Technologies
Service
Energy & Automation, Inc.
Interaction
M
Monitoring
I
Interaction
D
Diagnostics
A
Analysis
S
Service
 Interact with local maintenance people during normal
maintenance or troubleshooting
Mining Technologies
Energy & Automation, Inc.
Diagnostics
M
Monitoring
I
D
Interaction
Diagnostics
A
S
Analysis
Service
 Connect to experts from BI or Siemens at the speed
of the Internet for diagnostics and troubleshooting
 Complete toolset to support all diagnostic operations
 On line software upgrades
Mining Technologies
Energy & Automation, Inc.
Analysis
M
Monitoring
I
Interaction
D
Diagnostics
A
Analysis
S
Service
 Data correlation produces easy to use recommendation
reports
 Statistical data bases predict problems before they occur
thereby reducing down time
 Recommendation reports include lists of required parts as
well as maintenance procedures
Mining Technologies
Energy & Automation, Inc.
Service
I
M
Monitoring
Interaction
D
Diagnostics
A
Analysis
S
Service
 Hourly service and cost savings service packages available
Have one custom designed for you!
Mining Technologies
Energy & Automation, Inc.
Basic SiRAS Operation - Shovel Side
Remote I/O on Shovel
connected via Profibus
HMI
Touch screen Display
PC RACK
Wireless Ethernet
Station
Ethernet
Ethernet
Wireless
Ethernet
SLOT PLC S7
Ethernet card
Shovel Maintenance
Computer
Shovel
Access
Point
Processor
Software allows to run all functions
of the Shovel Maintenance PC
remotely by remapping the I/O
vectors (similar to “PC Anywhere”)
SiBAS Control Rack
Local
Processor
Executes
Diagnostics
Second Static Hard Disk w/
Diagnostic Application
Programs & Diagnostic Cache
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Connected via internal bus
Connected via monitor
interface (serial link)
Basic SiRAS Operation - Mine Office
and Internet
Energy & Automation, Inc.
Secondary Tower
- for Direct LOS, if required.
- can be moved around
- can be Solar powered
The Mine Host Provides
the connection to the
outside world and is also
available as a monitoring
station.
Main Tower
(Range 20 km)
ISP
Mine Connection
to Internet
Radio tower
Access Point
Wireless Ethernet
Station / repeater
Internet
Hub
Software
Firewall
Any PC with Internet connection
can access the shovel
Radio tower
Ethernet
Mine Host Computer
with Internet address
Main Tower
Booster
Access Point
Shovel Wireless
Ethernet Station
Ethernet
Access Point
Mine Wireless
Ethernet Station
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Mine Computer on LAN
Telephone
Dial up is also
possible
Any PC on the Mine
Network can access the
shovel
How does SiRAS work ?
Energy & Automation, Inc.
SiRAS Remote Diagnostics re maps the I/O vectors of the
Shovel Maintenance computer to a remote computer. As a result :
 All Machine Functions are available remotely. The remote operator sees the
same as the local electricians.
 The remote operator can communicate with the local electrician by printing
messages on the screen. He can also manipulate the cursor to point out
problems to the local electrician. The local electrician can ask questions
using the same method.
 Diagnostic software can be configured remotely, downloaded to the shovel,
and activated by the local electrician. Then the remote operator can
immediately analyze results.
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Energy & Automation, Inc.
Internet Access
 Any computer with an Internet connection
and the right password
can access the Mine Host PC
which runs the Shovel Maintenance PC remotely.
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Wireless Ethernet Pit Configuration I
Complete Coverage of a Large Pit can be obtained by a
single tower if there is a line of sight vantage point, such as
the dispatch office.
Radio tower
Booster
To mine Network
Access Point
Mining Technologies
Energy & Automation, Inc.
Energy & Automation, Inc.
Wireless Ethernet Pit Configuration II
Complete Coverage of a Large Pit can be obtained by
ringing the pit with a "data bridge". In this configuration,
each bridge is linked with an access point, the bridges talk to
each other, and the access points talk to the machine.
Radio tower
Access Point
Radio tower
Bridge
Radio tower
Access Point
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Access Point
To mine Network
Bridge
Radio tower
Bridge
Access Point
Bridge
Remote Monitoring for other Mine
Equipment
Dragline
Simoverts
Energy & Automation, Inc.
Other
Manufacturer PLC
or Discreet Logic.
Simoreg Exciter or
Drill Drive
Profibus
Real Time Data
Gathering
Diagnostic Computer
Logic Data Gathering
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Standard SiRAS Hardware Package –
One Time Cost
Energy & Automation, Inc.
On Shovel / Dragline
 Maintenance computer upgrade for Remote Diagnostics including software
 Shovel access point with wireless Ethernet station
Ethernet Link
 Wireless Ethernet repeater station for intermediate tower (requ. control power)
In Mine Office
 Mine office access point with wireless Ethernet station
 Host computer for the mine office including software. This computer is the gateway to the
shovel / dragline maintenance computer and is connected to the mine’s LAN and the Internet.
Engineering Support
 Consultation with local ISP personnel to optimize configuration of radio towers, and secure
connection to the mine’s LAN, etc.
 Complete turn key installations are available.
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MIDAS Service Packages –
Monthly Fee
Standard Package
Energy & Automation, Inc.
M A
D S
Monitoring
Link Checking
 The data link operation is checked daily via the Internet
Basic Machine Monitoring
Analysis
Diagnostics
 The machine is monitored daily. Any condition that might lead to failures is
flagged and the mine is notified.
 Summary and detail fault reports are created.
 Motion faults trigger trace recordings which can be viewed for further analysis.
 All significant control warnings (e.g. line voltage low) are summarized and
available for trend analysis.
 Statistics are compiled weekly / monthly and transmitted to the mine.
Software Up dates
 Unlimited software up dates
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Service
Energy & Automation, Inc.
IGBT 495-BII Shovel Event Report
 Aitik Mine, Boliden, Gällivare, Sweden
Reporting Period: 2002/01/05 03:12:55 to 2002/01/07 12:42:33
Report shows 10 messages, which took place in 6 events
**************************************************************************
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Energy & Automation, Inc.
IGBT 495-BII Shovel Event Report
FAULT EVENT Comprised of the Following 2 Message(s)
2002/01/07
12:42:33
SIB
352
HOIST BRAKING TOO LONG
2002/01/07
12:42:33
CDA
1149
HOIST FAULT (SEE MAINTENANCE STATION)
Trace file recorded at the time of the fault.
Mining Technologies
Energy & Automation, Inc.
IGBT 495-BII Shovel Event Report
FAULT EVENT Comprised of the Following 2 Message(s)
2002/01/07
09:28:51
SIB
221
OVERSPEED CROWD
2002/01/07
STATION)
09:28:50
CDA
1150
CROWD FAULT (SEE MAINTENANCE
Trace file recorded at the time of the fault.
Mining Technologies
Energy & Automation, Inc.
Other MIDAS Service Packages
In addition to the Standard Package we offer:
M
Monitoring
I
Interaction
Troubleshooting Assistance/Interaction (SiRAS-I)
 Available on a per call / hourly basis or in multiple hour packages.
A
Preventive and Reliability Centered Maintenance (SiRAS-A)
 Track operating hours of equipment for maintenance planning
 Monitor temperature / vibration signatures for preventive and reliability centered
maintenance.
Production Monitoring (SiRAS-M)
 Material movement are recorded using the load weigh system.
 Can be programmed to cover other areas of interest, e.g. the average swing angle,
average cycle time, etc.
Mining Technologies
Analysis
Energy & Automation, Inc.
Booked Projects
 Boliden, Sweden
495B Shovel
11/01
 Disputada, Chile
495B Shovel
01/02
 Peak Downs, Australia
2570 Dragline
02/02
 Albian Sands, Canada
3x495B Shovel
09/02
 Proposals for shovels at Lee Ranch, NM, Antamina, Chile,
Coteau Properties, ND
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
 Shovel
access point
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
 Shovel
antenna
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
 Mine office
computer
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
 Siemens
support
Mining Technologies
Energy & Automation, Inc.
SiRAS and MIDAS
…have more fun with SiRAS and MIDAS
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