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MINING USER CONFERENCE, MAY 3-5, 2017

Vale Itabira CaseOperating and maintaining digital substations based on IEC 61850

Leandro Monaco, Global Product Manager Operations & Electrical Control – System 800xA

Vale – Company Overview

What is IEC 61850?

SAS Vale Itabira overview

How does Vale Itabira SAS allows reduce Operational Expenditures (OPEX)?

Protection and zone selectivity study

Troubleshooting and root cause analysis

Remote operation and monitoring

Additional features that ensure reduced OPEX and ROI

Benefits

May 3-5, 2017 Mining User Conference 2017, StockholmSlide 2

Agenda of presentation

Vale is a private-sector, publically traded company, headquartered in Brazil and present in around 30 countries

Vale – Company overview

Mining User Conference 2017, StockholmSlide 3May 3-5, 2017

Created by the Brazilian federal government on June 1st 1942, with its operations restricted to the state of Minas Gerais.

In its first year, it produced 40,000 tons of iron ore, the same amount it now ships out per hour.

Privatized on May 6th 1997.

Global standard for electrical substation automation and power distribution systems

What is IEC 61850?

May 8, 2017 Slide 4

Interoperability

– Communication for protection & control between IEDs from different vendors

Freedom of configuration

– The ability of each vendor to use different methods in the internal programming of the IEDs, as long as it obeys the goal of interoperability

Long-term stability

– Ability of communication protocols to remain updated in front of technological advances

Based on 3 goals

Substation Automation System in numbers

SAS Vale Itabira overview

May 8, 2017 Slide 5

452 IED’s

21 Substations

– 02 Primary Substations of 230kV

– 02 Substations of 69kV

– 17 Substations of 13.8kV

25 Servers4.806 Tags

26 Workstations

155 Users

21 HMI Panel

First project delivered in 2010

3 Concentration Plants

61850

Vale Itabira SAS Case Study

How does Vale Itabira SAS allows reduce Operational Expenditures?

May 8, 2017 Slide 6

IEC61850 Benefits Vale Itabira cases

Remote Problem Solving

Faster Troubleshooting

Safety for Staff

Optimized Systems

Connect substations

Less maintenance Costs

Energy efficiency & asset optimization

Information readily available

Reduces different technologies




How long and which activities would be required?


Mining User Conference 2017Slide 7

Electrical team only goes to substation when needed


May 8, 2017 Slide 8

Logic and parameterization a right-click away, saving time from maintenance team



Average time for surveying the protection parameters of the 18 IEDs into 2 substations



Total time for 2 substations and 18 IEDs: 52 min

Start time

End time

Description

10:00 10:01 Communicate with machine 10.16.4.156 and enter access password

10:01 10:05 Opening PCM600 software within environment 10.16.4.156

10:05 10:07 Open the Substation Archive Base SE1215CN01

10:07 10:15 Communicate with relay UY1215CN501, choose the directory and save the settings

10:15 10:21 Time spent with directory difficulty (required to archive settings)

10:22 10:32 Communicate with relay UY1215CN502 to UY1215CN06, enter password and save settings

10:32 10:33 Close substation file SE1215CN01

10:33 10:34 Open the Substation Archive Base SE1475CN01

10:34 10:50 Communicate with relays UY1475CN501 to UY1475CN512 and save to mapped directory

10:51 10:52 Close Machine 10.16.4.156

Risks inherent to the displacement (approx. 6 km round trip)

Exposure to the high voltage in substations (up to 13.8kV)

Need to go up and down stairs

Risk and activities eliminated



No need to use of helmet, glasses, protection clothes

No need to carry equipment such as laptops and network cables

Fill in risk assessment form

Eliminated Risks Eliminated Activities

Overview from the entire electrical system in the control room



Same information locally and remotely allowing faster and safer troubleshooting



x

61850

System overview Remote information about interlocks and protection

Same information locally and remotely allowing faster and safer troubleshooting



Instant messages for every operation in power system Alarm & Event lists with time stamps from IEDs

Automatic report generation



Troubleshooting, root cause analysis and correction at the same day

How to make sure that the users have the right knowledge?



Avoid operation mistakes and leverage team knowledge even with low frequency of use



Control, supervision, protection and measurement



Internal trainings for electrical maintenance and operation teams

Reduced the “fear of the unknown” and potentialized the benefits


Information integration to ensure reduced OPEX and ROI

CCTV

Historian

Condition Monitoring

Energy Management

Additional features



CCTV

Historian


Energy Management

Additional features

Safer data collection

– Electrical data in real time and from a safe location

Productivity

– Analyze each set of equipment: consumption per ton of ore

Increased operating time

– Shorter maintenance shutdowns, reducing the risk of human failure

Cheaper and safer

– Savings of 600 km of electric cables

Simplified operation

– Change protection parameters via software and automatic system fault reports

Operating and maintaining digital substations based on IEC 61850

Benefits


IEC61850 is present in almost every Vale plant in Brazil!

Source: vale.com/brasil/EN/aboutvale/news/Pages/projeto-s11d-utiliza-tecnologia-inovadora-automacao-subestacoes-eletricas.aspx

http://www.vale.com/brasil/EN/aboutvale/news/Pages/projeto-s11d-utiliza-tecnologia-inovadora-automacao-subestacoes-eletricas.aspx

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