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Achieving Full Autonomy in Control

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Global Operations Approx.10,000 engineering staff

CANADA

St. John’s, Newfoundland & Labrador

Sorel-Tracy, Québec

Sudbury, Ontario

Toronto, Ontario

Vancouver, British Columbia

Winnipeg, Manitoba

New York, New York

Pensacola, Florida

Phoenix, Arizona

Pittsburgh, Pennsylvania

Sacramento, California

San Diego, California

San Francisco, California

Seattle, Washington

Tampa, FloridaAntofagasta, Chile

Belo Horizonte, Brazil

Lima, Peru

Rio de Janeiro, Brazil

Santiago, Chile

São Luís, Brazil

São Paulo, Brazil

Newcastle

Perth

Townsville

Wollongong

Adelaide

Brisbane

Gladstone

Mackay

Melbourne

AUSTRALIA

MIDDLE EAST

SOUTH

AMERICASOUTH AFRICA

Amherst, New York

Baltimore, Maryland

Boston, Massachusetts

Buffalo, New York

Cleveland, Ohio

Denver, Colorado

Houston, Texas

Millburn, New Jersey

Calgary, Alberta

Halifax, Nova Scotia

Mississauga, Canada

Montréal, Québec

Niagara Falls, Ontario

Oakville, Ontario

Saskatoon, Saskatchewan

CHINA

NEW CALEDONIA

Johannesburg

Pretoria

Cape Town

London, England

Moscow, Russia

St. Petersburg, Russia

EUROPE

INDIANew Delhi

Beijing

Shenyang

Shanghai

USA

Abu Dhabi, UAE

Al Khobar, Saudi Arabia

Sohar, Oman

Nouméa

INDONESIAJakarta

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THERMAL

COAL

WATER

INFRASTRUCTURE SERVICES

PORTS AND MARINE TERMINALS

RAIL & TRANSPORTATION SYSTEMS

Hatch’s Business Units

NUCLEAR

NON-FERROUS

LIGHT METALS

MINING & MINERAL PROCESSING

INDUSTRIALMINERALS

IRON & STEEL RENEWABLE POWER

TRANSMISSION & DISTRIBUTION

OIL & GAS

en

erg

y

infra

stru

ctu

re

me

tals

IRON ORE

>US$35 billion of projects under management

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Agenda

• Why is Full Autonomy in control important?

• Barrier/Challenge to Full Autonomy in Control

• Overcoming these barriers using Hatch Integrated Control

(HIC) approach

• Case Study Example: Hatch Stockyard Automation

• Other Hatch Case Studies using HIC approach

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Why is Full Autonomy in Control Important?

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Case Study : Stockyard Operation

• Operation : Bulk material handling stockyard. Capital

intensive and large.

• Equipment : Stacker and reclaimer mobile machines. These

mobile machines working on common stockpiles in the

stockyard.

• Control : Manually operated.

• Stockpile : Stockpile layout, size, product type according to

market requirements

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Case Study : Stockyard Operation

What impacts performance?

• Performance/throughput based on operators acting upon

instructions.

• Variations and inconsistencies highly likely due to the “human

factor”. Direct impact on productivity.

• Operational capacity and flexibility would not be at ideal

levels, meaning potential lost production.

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Traditional Automation

For such a facility, “Traditional” automation can make a

difference.

• Automatic operation of an equipment. Less operator

intervention.

• Higher productivity, moving machines optimally to the right

spot, working the buckets at the right speed, etc.

• More visibility. Faster response to issues.

• Fewer personnel requirements

• Fewer mistakes

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What are the limits of Traditional Automation

• Limited alignment with business objectives and workflow

• Automation scope is limited within equipment items or plant

area

• Limited allowance for abnormal scenarios

• Missed improvement opportunities

• Systems not structured for optimisation and expansion.

Minimal flexibility.

Full Autonomy can address the above and more....

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Challenge/Barrier to Full Autonomy in Control

Traditional automation is single equipment focused; rather than overall system and not inclusive of business processes (incomplete understanding of the client’s full business and operational workflow and objectives)

Traditional automation focuses mainly on normal operational scenarios; failure to seize improvement opportunities from handling and recovery from abnormal scenarios

Operational support often challenging due to low visibility and diagnostics

System complexity and skill retention due to high turn over of operational staff can impact ability to maintain

Lack of

Coordination

Missed

Opportunities

System

Complexity

Maintainability

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Overcoming Challenges/Barriers

through Hatch Integrated Control

Embed business, operational and process knowledge into an integrated and

coordinated control scheme

Consider and design for abnormal condition management to reduce disruption and improve system recovery time to steady state operation

Formulate and parameterise the solution to provide a configurable system

with visible diagnostics to simplify maintenance and enhancements throughout the plant lifecycle

Ensure high system availability via a thorough engineering, verification and testing process (IEEE 12207)

Lack of

Coordination

Missed

Opportunities

System

Complexity

Maintainability

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Case Study : Stockyard Operation

How can Hatch Integrated Control improve the

operation?

Focus areas:

• Safe autonomous operation without machine collision

• Efficient production

• Maximise stockyard capacity and flexibility

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Case Study : Stockyard Operation Challenges

Stockyard capacity dependent on ability of mobile machines to

work safely and close together

Stockyard flexibility dependent on ability to define and manage

the stockpile ore type, size, shape, stacking pattern, etc.

Stacking performance (consistency in stockpile geometry, size)

has a direct effect on reclaiming performance

Variability of operational performance due to manual operation

System maintainability and availability can significantly impact

productivity

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Case Study : Stockyard Operation

How can Hatch Integrated Control improve the

operation?

Via the Hatch Stockyard Automation (HSA) System

Embeds Stockyard Management System and Machine

Protection System

Operators provided high flexibility in defining and configuring

stockyard parameters

Advanced automation for unmanned operation. Variability

minimised and capacity utilisation maximised

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Case Study : Stockyard Operation

How can Hatch Integrated Control improve the

operation?

Via the Hatch Stockyard Automation (HSA) System

System engineered to provide configuration changes without

modifying the core underlying software. Extensive use of

generic algorithms

Robust and high reliability system

Workflow simplified and efficiency improved

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Hatch Stockyard Automation (HSA) System

Reclaimer PLC

Stockyard &Mobile Machines

Geometry

Stockyard Management System

1-1-51-1-1

1-2-1

1-3-1

1-1-2

Stockyard (Stockpile: Yard-Row-PileNo)

1-4-1

POWER

Allen-BradleyQUALITY

RUN

BAT

I/O

Rs232

OK

RUN PROGREM

Logix5550 DC INPUT

O

K

ST

ST

ST

ST

0 1 2 3 4 5 6 7

1 1 1 1 2 2 2 2

6 7 8 9 0 1 2 32 2 2 2 2 2 3 3

4 5 6 7 8 9 0 1

1 1 1 1 1 1

0 1 2 3 4 58 9

DC INPUT

O

K

ST

ST

ST

ST

0 1 2 3 4 5 6 7

1 1 1 1 2 2 2 2

6 7 8 9 0 1 2 32 2 2 2 2 2 3 3

4 5 6 7 8 9 0 1

1 1 1 1 1 1

0 1 2 3 4 58 9

DC OUTPUT

O

K

ST

ST

0 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15

POWER

Allen-BradleyQUALITY

RUN

BAT

I/O

Rs232

OK

RUN PROGREM

Logix5550 DC INPUT

O

K

ST

ST

ST

ST

0 1 2 3 4 5 6 7

1 1 1 1 2 2 2 2

6 7 8 9 0 1 2 32 2 2 2 2 2 3 3

4 5 6 7 8 9 0 1

1 1 1 1 1 1

0 1 2 3 4 58 9

DC INPUT

O

K

ST

ST

ST

ST

0 1 2 3 4 5 6 7

1 1 1 1 2 2 2 2

6 7 8 9 0 1 2 32 2 2 2 2 2 3 3

4 5 6 7 8 9 0 1

1 1 1 1 1 1

0 1 2 3 4 58 9

DC OUTPUT

O

K

ST

ST

0 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15

Stacker PLC

POWER

Allen-BradleyQUALITY

RUN

BAT

I/O

Rs232

OK

RUN PROGREM

Logix5550 DC INPUT

O

K

ST

ST

ST

ST

0 1 2 3 4 5 6 7

1 1 1 1 2 2 2 2

6 7 8 9 0 1 2 32 2 2 2 2 2 3 3

4 5 6 7 8 9 0 1

1 1 1 1 1 1

0 1 2 3 4 58 9

DC INPUT

O

K

ST

ST

ST

ST

0 1 2 3 4 5 6 7

1 1 1 1 2 2 2 2

6 7 8 9 0 1 2 32 2 2 2 2 2 3 3

4 5 6 7 8 9 0 1

1 1 1 1 1 1

0 1 2 3 4 58 9

DC OUTPUT

O

K

ST

ST

0 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15

HMI

Stockpile Edit

Stockpile Archive

Sto

ckip

ile D

ata

Sto

ckip

ile E

dit

1-4-3

1-4-3

Check-in Updates S

tockpile file,

Machine positins

Check-out Stockpile

file, a

nti-collis

ion motio

n

permiss

ives

Check-out Stockpile file, anti-collision motion

permissives

Check-in Updates Stockpile file,

Machine positins

Stockpile Edit Stockpile Custody

Machine-Machine, Machine Stockpile

Anti-collision

Stockyard Display

GPSGPS

Commands/Instruction

1. Commands/Instructions to

simplify workflow

• Stockpile location

• Footprint

• Product type

• Stacking pattern

2. Control characteristics to

allow optimisation

• Repose angle

• Density

3. Coordination Information to

improve efficiency

• Last stacked position

• Last reclaimed position

• Last machine

Operator checks out the

stockpile to the stackerOperator checks in the

stockpile

Operator checks out the

stockpile to the reclaimer

Commands/Instruction

1. Commands/Instructions to

simplify workflow

• Stockpile location

• Footprint

• Product type

• Stacking pattern

2. Control characteristics to

allow optimisation

• Repose angle

• Density

3. Coordination Information to

improve efficiency

• Last stacked position

• Last reclaimed position

• Last machine

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Hatch Collision Protection System

• Provide safe operation of machines through centralised

monitoring of mobile machine positions and motions

• Improve stockyard utilisation by allowing closer machine

operation – use dynamic protection envelope which is a

function of velocity/direction

• Improve system availability through the use of GPS data with

machine position encoders as back up

• Provide clear Human Machine Interface with diagnostics to

facilitate understanding of system behaviour

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Hatch Stockyard Automation - Achievements

Implemented at one of the world largest stockyard, achieving:

Full unmanned stockyard mobile machine operation (labour

reduction of approx. 4 operators per machine)

Improved stockyard flexibility (stockpile layout can be easily

reconfigured by operator; allowing client to adjust the stockpile

size to improve reclaiming efficiency and adjust inventory

location to suit market conditions)

System reliability and dynamic envelope of collision protection

improve the stockyard capacity through closer machines

operation and less disruption due to system outages

Productivity improvement through removal of variability due to

manual operation and advanced control automation

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Simplify Maintenance through Configuration

Management

Design systems to eliminate the need to modify the core software;

modifications made through configuration of attributes e.g.

• Stockpile Management System allows operator to configure for

each stockpile:

– Size

– Position

– Permitted Ore type (prevent contamination)

– Permitted Stacking Pattern and Reclaiming Pattern

• Collision Protection System allows the engineer to configure each

machine without the need to modify collision protection algorithms:

– Mobile machine rail location and permitted movement area

– Geometrical dimension of each mobile machine

– Maximum deceleration rate of each mobile machine

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Improving Availability

• By parametrising the software implementation into a set of

generic algorithms and a set of configurable attributes; after initial

detailed testing, future modifications can be implemented through

configuration changes rather than core software changes – this

significantly improves system availability and lowers risk

• A bulk material handling supervisory control system called HPT

developed by Hatch using this principle has achieved an

availability better than 99.95, with average downtime of less than

1 hr p.a. over the last 10 years despite over 26 stages of

expansion (through configuration changes)

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Track Record of Hatch Integrated Control Approach

• Review of a mineral sands operation culminating in the delivery of

AUD$3.3 million p.a. productivity improvement through the integrated

control approach

• Review and implementation of an integrated control strategy to

coordinate the crushing and milling areas enabling the operation to

achieve its nameplate capacity.

• The HPT Route Control system has delivered a 6% productivity

improvement and facilitated more than 20 stages of expansion of a

bulk ore handling port, with system availability better than 99.96%.

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Track Record of Hatch Integrated Control Approach

• The Hatch Reclaimer control strategy that has successfully delivered

a performance improvement resulting in savings of over AUD$1.2

million p.a. for demurrage costs.

• Hatch Stockyard Automation (HSA) which has enabled safe and

efficient unmanned operation of mobile machines within a stockyard,

whilst improving overall efficiency and consistency at one of the

largest coal ports in the world.

• The Hatch Virtual Spud (HVS) control technology which allows

‘spudless’ dredge operation delivering productivity improvements of

10-20% by increasing the continuous mining area approx 9 fold and

removing non-productive time due to spud walk and crabbing

movements.

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For more

information,

please visit

www.hatch.ca