ENG450 – Engineering Internship
Final Year Engineering Internship Report
Murdoch Engineering Faculty of Minerals and Energy ENG450 – Engineering Internship
Prepared By: Brad Smith
Academic Supervisor : Associate Professor Graeme Cole
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Table of Contents 1.0
DISCLAIMER ................................................................................................................................................. 7
2.0
INTRODUCTION ........................................................................................................................................... 8
2.1
OBJECTIVES ................................................................................................................................................... 8
2.2
REPORT FOCUS .............................................................................................................................................. 8
2.3
COMPANY INFORMATION .............................................................................................................................. 8
3.0
LIST OF ABBREVIATIONS ......................................................................................................................... 9
4.0
PROJECT OUTLINE ..................................................................................................................................... 9
4.1
FUNCTIONAL SEQUENCE – HEMATITE ......................................................................................................... 10
4.1.1
Train Unloading and Stockpiling........................................................................................................... 10
4.1.2
Reclaiming and Ship Loading ................................................................................................................ 11
4.2
FUNCTIONAL SEQUENCE – MAGNETITE ....................................................................................................... 11
4.2.1
Train Unloading and Stockpiling........................................................................................................... 11
4.2.2
Reclaiming and Ship Loading ................................................................................................................ 11
4.3 5.0
STORAGE FACILITY DESIGN PARAMETERS .................................................................................................. 12 CONVEYOR DESIGN ................................................................................................................................. 14
5.1
FUNCTION.................................................................................................................................................... 14
5.2
SAFETY........................................................................................................................................................ 14
5.3
CONVEYOR DESIGN ..................................................................................................................................... 14
5.4
TRIPPER DESIGN .......................................................................................................................................... 15
6.0
SAFE CONVEYOR DESIGN ...................................................................................................................... 16
6.1
CONVEYOR STOPPING ................................................................................................................................. 16
6.1.1
Belt Drift Switch..................................................................................................................................... 17
6.1.2
Belt Rip Detector ................................................................................................................................... 17
6.1.3
Blocked Chute Switch ............................................................................................................................ 17
6.1.4
Speed Sensing Element .......................................................................................................................... 17
6.2
EMERGENCY STOPS ..................................................................................................................................... 18
6.2.1
Pull Wire Switch .................................................................................................................................... 18
6.2.2
E/Stop..................................................................................................................................................... 19
6.2.3
Emergency Push Button (EPB) .............................................................................................................. 19
6.3
START-STOP CONTROLS .............................................................................................................................. 19
6.3.1
Local Control Panel............................................................................................................................... 19
6.3.2
Start Up Warning................................................................................................................................... 20
6.4
ISOLATING ................................................................................................................................................... 20
6.5
TRIPPER CONTROLS ..................................................................................................................................... 21
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6.5.1
Local Control Panel............................................................................................................................... 21
6.5.2
Remote Control Panel............................................................................................................................ 21
6.5.3
Tripper Position Sensor ......................................................................................................................... 22
6.5.4
Tripper Travel Limit .............................................................................................................................. 22
6.5.5
Ultrasonic Level Sensor......................................................................................................................... 23
6.5.6
Catenary Snag Sensor............................................................................................................................ 24
6.6
DUST SUPPRESSION ..................................................................................................................................... 24
6.6.1
Dry Dust Controller............................................................................................................................... 24
6.6.2
Wet Dust Controller............................................................................................................................... 25
7.0
ELECTRICAL DESIGN .............................................................................................................................. 26
7.1
HIGH VOLTAGE ........................................................................................................................................... 26
7.2
SINGLE LINE DIAGRAMS ............................................................................................................................. 27
7.2.1
Updating the Single Line Diagram ........................................................................................................ 27
7.2.2
Cable Sizing ........................................................................................................................................... 29
7.3
SWITCHROOM .............................................................................................................................................. 30
7.3.1 7.4
Schematic............................................................................................................................................... 31 INSTRUMENTATION AND CONTROL PACK .................................................................................................... 34
7.4.1
Instrumentation and Controls Layout .................................................................................................... 35
7.4.2
Connection diagram .............................................................................................................................. 36
7.4.3
Schematic............................................................................................................................................... 41
8.0
LIGHTING DESIGN .................................................................................................................................... 42
8.1
CONVEYOR GALLERIES ............................................................................................................................... 43
8.2
TRANSFER TOWERS ..................................................................................................................................... 47
8.3
MCC AND TRANSFORMER COMPOUND ........................................................................................................ 49
8.4
STORAGE SHED ........................................................................................................................................... 51
8.5
STAIRS AND HANDRAIL ............................................................................................................................... 51
8.6
EMERGENCY LIGHTING ................................................................................................................................ 51
8.7
DESIGN RESULTS ......................................................................................................................................... 51
8.8
LIGHTING AND SMALL POWER DRAWINGS .................................................................................................. 52
9.0
PLC DESIGN................................................................................................................................................. 56
9.1
ETHERNET ................................................................................................................................................... 56
9.2
DEVICENET.................................................................................................................................................. 57
9.3
MODBUS ...................................................................................................................................................... 58
9.4
CONTROLNET .............................................................................................................................................. 58
9.5
INTERNSHIP CONTRIBUTION ........................................................................................................................ 59
10.0
REFERENCES .............................................................................................................................................. 60
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11.0
BIBLIOGRAPHY ......................................................................................................................................... 61
12.0
APPENDIX A – KIOP ELECTRICAL DRAWINGS................................................................................ 62
13.0
APPENDIX B – GPA DRAWINGS ............................................................................................................. 63
14.0
APPENDIX C – SAFE-T-DRIFT DATA SHEET ...................................................................................... 64
15.0
APPENDIX D – SAFE-T-RIP DATA SHEET............................................................................................ 65
16.0
APPENDIX E – NHP PULL WIRE SWITCH DATA SHEET ................................................................. 66
17.0
APPENDIX F – IFM DATA SHEET........................................................................................................... 67
18.0
APPENDIX G – START UP WARNING DATA SHEET ......................................................................... 68
19.0
APPENDIX H – CABLE CALCULATION EXAMPLES......................................................................... 69
20.0
APPENDIX F – 3D MODEL SCREENSHOTS.......................................................................................... 70
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Table of Figures and Tables FIGURE 1: STARTUP WARNING SIREN.............................................................................................................. 21 FIGURE 2: REMOTE CONTROL PANEL RECEIVER ....................................................................................... 23 FIGURE 3: ULTRASONIC LEVEL SENSOR......................................................................................................... 26 TABLE 1: SINGLE LINE DRAWING LIST............................................................................................................ 30 TABLE 2: VSD SCHEMATICS DRAWING LIST.................................................................................................. 38 TABLE 3: DOL SCHEMATIC DRAWING LIST ................................................................................................... 40 TABLE 4: EXAMPLE OF INSTRUMENTATION AND CONTROLS PACK DRAWINGS............................. 41 TABLE 5: INSTRUMENTATION AND CONTROLS DRAWING LIST ............................................................ 42 TABLE 6: CONNECTION DIAGRAM DRAWINGS............................................................................................. 50 TABLE 7: LIGHTING LEVELS FROM AS1680 .................................................................................................... 54 FIGURE 4: STANDARD CONVEYOR LIGHTING DESIGN PLAN................................................................... 56 FIGURE 5: STANDARD CONVEYOR LIGHTING DESIGN ISOMETRIC ...................................................... 56 FIGURE 6: STANDARD CONVEYOR LIGHTING DESIGN RENDERED MODEL ....................................... 57 FIGURE 7: CONVEYOR CV520 LIGHTING DESIGN PLAN ............................................................................. 58 FIGURE 8: CONVEYOR CV520 LIGHTING DESIGN ISOMETRIC................................................................. 58 FIGURE 9: CONVEYOR CV520 LIGHTING DESIGN RENDERED MODEL.................................................. 59 FIGURE 10: TRANSFER TOWER LIGHTING DESIGN PLAN ......................................................................... 60 FIGURE 11: TRANSFER TOWER LIGHTING DESIGN ISOMETRIC............................................................. 60 FIGURE 12: TRANSFER TOWER LIGHTING DESIGN RENDERED MODEL.............................................. 61 FIGURE 13: SWITCHROOM LIGHTING DESIGN PLAN.................................................................................. 62 FIGURE 14: SWITCHROOM LIGHTING DESIGN ISOMETRIC ..................................................................... 62 FIGURE 15: SWITCHROOM LIGHTING DESIGN RENDERED MODEL ...................................................... 63 TABLE 8: LIGHTING DESIGN RESULTS............................................................................................................. 64 TABLE 9: POWER DESIGN REQUIREMENTS ................................................................................................... 66 TABLE 10: LIGHTING AND SMALL POWER DRAWING LIST ...................................................................... 67 FIGURE 16: ETHERNET NETWORK .................................................................................................................... 70 FIGURE 17: CONTROLNET NETWORK .............................................................................................................. 72
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1.0
Disclaimer
Confidentiality is required for this document as stipulated in the Internship Contract.
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2.0
Introduction
2.1
Objectives
The purpose of this report is to demonstrate that the intern actively participated and learnt while conducting the engineering internship.
2.2
Report Focus
The focus of this report is the Karara Iron Ore Project. The report details the electrical engineering design of the new storage shed and associated facilities. Special attention is given to safe design to prevent injury to personnel or damage to equipment. The report will discuss theory of the electrical design and identify what the intern’s contribution was on the Karara Iron Ore Project.
2.3
Company Information
Maunsell AECOM is an engineering design firm that has expertise in the following fields: Buildings; Environment, Water & Civil Infrastructure; Minerals & Industry; Power & Energy and Transport. With a large parent company AECOM, Maunsell has been able to draw on a global pool of talent to become an industry leader in engineering design.
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3.0
List of Abbreviations
AS
Australian Standards
BF
Belt Feeder
CV
Conveyor
DWT
Dual Wagon Tipper
GPA
Geraldton Port Authority
KIOP
Karara Iron Ore Project
MGI
Mount Gibson Iron Ore
4.0
Project Outline
Maunsell AECOM was selected to produce the detailed design for a new minerals handling and storage facility in Geraldton. The minerals will be stored in 2 sheds to be located at the Geraldton port on the Geraldton Port Authority’s (GPA) premises. The minerals will be transported into the GPA from the Mid West region of WA by rail. The Karara mine site is located approximately 320km North-North-East of Perth and 215km East-South-East of Geraldton in the shire of Perenjori. The GPA currently has an existing network of conveyors that move minerals from the train unloader to the storage sheds, then to the available ship loaders. Most of the conveyors are owned and operated by the GPA. However, Mount Gibson Iron (MGI) has a storage facility also located on the GPA premises that has associated conveyors.
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Maunsell will be designing both the Hematite and Magnetite storage sheds, the Dual Wagon Tipper (DWT), Berth 7 Ship Loader and all associated conveyors. includes only the Hematite shed and the associated conveyors.
Stage1
Stage 2 works will
complete the outstanding tasks.
4.1
Functional Sequence – Hematite
4.1.1
Train Unloading and Stockpiling
Hematite minerals may be supplied by two different train unloaders, the GPA train unloader or the Dual Wagon Tipper (DWT).
The GPA train unloader uses bottom
discharge cars to release the minerals onto the conveyor system that will move the minerals to conveyors CV702 via CV601. The DWT uses flat bottom cars that are tipped to release the minerals onto feeders that transfer the minerals onto CV701 which transfers the minerals onto CV702. Please refer to Appendix F – 3D Model Screenshots while reading the following section. CV702 is used in both unloading systems and therefore only one unloader may be used at a time. CV702 moves the minerals approximately 357m and transfers the minerals using gravity onto CV703. CV703 is 94m long and transfers minerals using gravity onto CV704. The transfer point for CV703 and CV704 is located inside the Hematite shed. CV704 is a shuttle conveyor that will change position in order to be used to direct the minerals to either the Hematite or Magnetite sheds.
In the “Hematite” position the
minerals from CV703 lands onto CV704 and is carried for 12 m and transferred using gravity onto CV705. Tripper conveyor CV705 runs the full length of the storage shed (166m) and will be able to transfer (using gravity) the minerals at discrete locations along CV705.
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4.1.2
Reclaiming and Ship Loading
The stored minerals will be reclaimed by front-end loaders and tipped onto the feeders. Two of the three feeders will be operational at one time, and will transfer the minerals using gravity onto CV520. The feeders are approximately 12m long and transfer the minerals onto CV520 using gravity. CV520 will move the minerals approximately 135m and transfer the minerals onto CV521 using gravity. CV521 travels approximately 82m to transfer the minerals onto CV522 using gravity. CV522 will move the minerals 166m to CV523 and transfer the minerals using gravity. CV523 will move the minerals 45m and transfer the minerals using gravity onto CV503 an existing GPA conveyor that feeds the Berth 5 shiploader.
4.2
Functional Sequence – Magnetite
4.2.1
Train Unloading and Stockpiling
The magnetite minerals will only be available via the DWT. The minerals will follow the same path as the Hematite unloaded from the DWT until it reaches the end of CV703. The Hematite then transfers onto CV704 in the “Hematite” position, the Magnetite will transfer onto tripper conveyor CV706. This is possible because CV704 in the “Magnetite” position will align the CV704 bypass chute with tripper conveyor CV706. CV706 will run into the Magnetite shed covering the full length of the shed. The minerals will be discharged at discrete locations using gravity into stockpiles for storage in the Magnetite shed. 4.2.2
Reclaiming and Ship Loading
Minerals from the Magnetite shed will be reclaimed using a drag-chain reclaimer that will transfer the minerals onto CV708.
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The magnetite may be transferred directly to the ship loader without being stored. CV706 will be able to transfer minerals onto CV707 bypass conveyor that would transfer the minerals directly to CV708. CV708 will transfer the minerals onto CV730 using gravity. As mentioned previously, Hematite may be transferred onto CV730 for ship loading to Berth 7. CV730 will transfer minerals onto CV731 using gravity. CV731 will transfer minerals onto the Berth 7 ship loader boom conveyor.
4.3
Storage Facility Design Parameters
The storage facility houses mined and processed minerals while until they are able to be loaded onto the transport ships. The storage shed and conveyors have a minimum specification as shown below:
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Hematite Storage Facility Material:
Hematite Iron Minerals – Lumps & Fine Particles
Storage Capacity:
170,000 tonnes
Facility Inloading Rate:
5,000 tph (design)
Facility Outloading Rate:
5,000 tph (design)
Magnetite Storage Facility Material:
Magnetite Concentrate
Storage Capacity:
170,000 tonnes
Facility Inloading Rate:
5,000 tph (design)
Facility Outloading Rate:
5,000 tph (design)
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5.0
Conveyor Design
5.1
Function
The conveyors are put in place to move the minerals from point A to point B at a designated rate. The reason for this is to minimise the time taken to move the minerals. Conveyors are also the lowest operating cost method of moving large quantities of bulk minerals. The main function of the tripper conveyor is to convey minerals from the feeding conveyor so that it may be stockpiled within the storage shed to be later reclaimed for ship loading. The tripper is a short upward incline portion of the conveyor, elevating and discharging the minerals while maintaining the continuity of the belt. The tripper needs to be a mobile wheel driven unit that can travel along the storage shed to allow for even and selective transferring of the minerals. In order to take advantage of gravity and the maximum storage capacity of the shed, the conveyor and tripper are located at the apex of the shed.
5.2
Safety
The conveyor and tripper are required by Australian standards to be designed manufactured, commissioned, tested and maintained by Australian Standards and other statutory regulations. AS1755 Conveyors – Safety Requirements, outlines safe practices for conveyor and conveyor systems design and refers to other appropriate standards. The mines safety act and the WA mining regulations are statutory regulations that detail further mandatory requirements.
5.3
Conveyor Design
For the KIOP project there are a few challenges for the design team. The project location is on a “brown fields” site, meaning that the storage shed is being designed for an existing site. The brown fields site provides restrictions on where new equipment and structures can be placed as they need to co-exist within an existing facility and infrastructure.
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Additionally, the conveyor system needs to be designed to accommodate two different minerals: Hematite and Magnetite. In order to correctly design power requirements two sets of calculations are required to determine the worst case scenario.
Other
considerations revolve around different material characteristics which may require different transfer point geometries and chute materials appropriate to both minerals.
5.4
Tripper Design
The purpose of the tripper is to discharge the conveyed material into the storage stock pile.
The tripper is also required to discharge the materials at specific locations to
regulate the stockpile level. A simple yet effective design is employed by Maunsell’s design engineers. This design also reduces the cost to the customer. Refer to drawing 1681-EL-DRG-1287 in Appendix A – KIOP Electrical Drawings. The tripper needs to be light and durable to maximise the loads imparted by the tripper onto the shed steel structure and maintain an economic structural solution.
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6.0
Safe Conveyor Design
The main purpose of the instrumentation when designing a conveyor system is to make the system safe for people and machinery while it is being used, maintained or repaired. Instrumentation also provides a greater level of control over the system which can lead to greater operating efficiency therefore saving money. When designing such a system there is a risk of over designing. A responsible engineer should design a functional system within the bounds of the available budget and overall project philosophy.
This approach is generally more difficult to achieve than the
“standard solution” but the end result will be more suitable for the application. The minimum safety requirements for designing a conveyor will be discussed below and can also be found in AS1755, WA mines regulation and the mines safety act.
6.1
Conveyor Stopping
When a conveyor is stopped for any reason, it should stop in the shortest time possible and remain stopped until started again (AS1755, 2000). Conveyor stops may occur as operational, protective or emergency stops. In each case AS1755 outlines the design criteria. Operational stopping is straight forward. The shut down sequence is activated and the conveyor is brought to a stop by the VSD reducing the current output to the motor. When the power is disconnected, the conveyor should remain stationary. This is achieved by a gearbox locking system that is called a “hold back”. Gravity prevents the conveyor from moving forward (as it is generally designed with an incline) and the hold back prevents the conveyor from moving backwards. Protective stops occur in a situation where damage or injury is likely to occur to equipment or persons in the near vicinity.
AS1755 (section 1.6, pg.7) describes a
protective stop as “A stop control provided for the protection of the conveyor or personnel from a hazard which, when activated, stops the conveyor and includes emergency stop controls.” Brad Smith – 30331929
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On KIOP protective stop controls include: Belt drift switches (BDS) Belt rip detector (BRD) Blocked chute switch (BCS) Speed sensing element (SSE) Catenary Snag Switch (CSS) A brief description of each is given below. 6.1.1
Belt Drift Switch
Belt drift switches are located on the side of the conveyor with the primary function to indicate when the conveyor is drifting off the conveyor idler supports. A signal is sent to the PLC that will activate a timer and after the timer, a fault condition is initiated and the conveyor stops the drifting belt before it causes damage or injury. Refer to Appendix C – Safe-T-Drift Data Sheet. 6.1.2
Belt Rip Detector
Belt rip detectors are used to signal to the PLC when the conveyor belt has been damaged or ripped. Therefore the BRD’s are generally located a few meters after the transfer point on a conveyor. This location is chosen because, the place where the belt is most likely to rip is at the transfer point, and therefore the rip is detected soon after occurring, and therefore any damage to equipment is minimised. This location is also where to objects are most likely to stab through the belt. See Appendix D – Safe-T-Rip Data Sheet 6.1.3
Blocked Chute Switch
The blocked chute switch becomes activated when the transfer chute from one conveyor to another becomes full and runs the risk of overflowing. This creates an alarm that will stop the conveyor. The protective stop will prevent spilling that could cause damage to equipment or injury to personnel. 6.1.4
Speed Sensing Element
The speed sensing element is used to indicate to the PLC that the conveyor is travelling too slowly. However, the PLC does not look for the under speed immediately at startup.
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A time delay (blanking interval) is allowed for the conveyor to start, once the timer runs out the flag is set. If the under speed sensor is activated another timer starts and at the end of this timer a fault condition is initiated and the conveyor is stopped. See Appendix F – IFM Data Sheet.
6.2
Emergency Stops
The definition of an emergency stop is defined by AS1755 (section 1.6, pg.6) as: “A manual or automatically operated system designed to stop a conveyor system in the shortest practicable time in an emergency.”
Devices used to provide sufficient emergency stop capabilities are: Pull-wire switch (PWS) E/Stop on the Local Control Panel (LCP) Emergency push button (EPB) 6.2.1
Pull Wire Switch
The pull wire switches are located on walkways that run adjacent to the conveyor and each pull wire section may be spaced up to 100m, (i.e. a double-sided pull wire switch can operate up to 200m). AS1755 also specifies where the pull wire switch is to be mounted along the conveyor. For grounded conveyors the pull wire switch should be mounted between 900mm and 1500mm above ground level. For elevated conveyors the height limit may be exceeded as long as the pull wire switch is below the sheer point of the conveyor (AS1755). In the event of an emergency, the pull wire is pulled, thereby disconnecting the hardwire electrical circuit to the VSD. When the hardwire circuit is interupted three different actions occur to stop the conveyor. First the main contactor that feeds power to the VSD is opened completely, thereby removing power to the VSD. Second, the PLC will receive the fault message from the pull wire switch via the digital input and then send a message to the VSD to stop operating. Third an internal hardwire that allows the Insulated Gate Bipolar Transistors (IGBT) to fire is broken, physically stopping the VSD operations even if the first two operations fail. For more information refer to Appendix E – NHP Pull Wire Switch Data Sheet
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6.2.2
E/Stop
Each conveyor has a local control panel that has an E/Stop button that is wired up to the same hardwire circuit as the pull wire switch. Therefore, if the E/Stop is pressed then the process to stop the conveyor is the same as the pull wire switch. 6.2.3
Emergency Push Button (EPB)
The emergency push button has only been used in one location, on CV704.
The
emergency push button functions in the very same manner as the E/Stop and pull wire switch. The emergency push button is generally located where there is some dangerous moving equipment that may require an immediate stop to prevent injury or damage to equipment.
6.3
Start-Stop Controls
In order for the storage facility to operate safely, sequential control of the conveyors is required for starting and stopping operations. The starts and stops can be operated via the PC control panel or operated at the local control panel (LCP) of each conveyor. In most operational circumstances the PC control panel will be used to start all the conveyors in the correct sequential order. The local control panel would be used when testing the conveyor or under special circumstances. 6.3.1
Local Control Panel
All conveyors have a local control panel (LCP) that is located at the head (drive) of the conveyor. The local control panel is one of the devices used to control the conveyor. A normal local control panel has two push buttons, one 2-position switch and an E/Stop push button. The two push buttons are used for start and stop operations. The 2position switch is used to select local or auto control and the E/Stop has been discussed previously. In some circumstance where the conveyor is reversible, a second switch is available to select forward or reverse. Conveyors are not the only devices to have local control panels, the direct online devices also have local control panel. These devices are generally smaller motors such as dust collectors or water pumps. Normally, the DOL local control panel has one push button,
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one 2-position switch and one E/Stop. The push button is used as the start and the 2position switch is used for the local and auto selection option. 6.3.2
Start Up Warning
AS1755 also requires that a prestart warning be given that a conveyor is about to operate. This requirement is met by installing a start up warning (SUW) unit that is controlled by the PLC digital output card. The start up warning is a siren accompanied by a flashing light to effectively warn nearby personnel that the conveyor is about to start. Refer to Appendix G – Start Up Warning Data Sheet.
Figure 1: Startup Warning Siren
6.4
Isolating
For safety during repairs and maintenance, an isolating device is connected in series between the source and the load (in most cases a motor). The isolator’s purpose is to totally remove power to the device. AS1755 clearly states that at least one form of isolation is to be installed for every conveyor drive and that device should be lockable in the open (isolated) position. The isolator should not be lockable in the closed position and is to be manually operated. The Mines Safety and Inspection Regulations1995 section 5.29 states that all electrical equipment on the mine site is provided with an isolating device.
This means that
isolating devices are included for all other motors such as those for dust collector sand
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water pumps. In most cases 2 such isolators have been provided per device; one at the motor control centre and the other a field isolator. The above standards don’t specify the location of the isolating device. In most cases the device will be isolated at the MCC. However, only authorised personnel have access to the switchroom. In order to provide a best practice design, Maunsell includes a second standalone isolator that is located very near to the device. This allows added safety for the person who is working on the equipment by providing a visual confirmation that the device is isolated.
6.5
Tripper Controls
As previously discussed, the tripper allows a cost effective manner to discharge the minerals into the storage shed. To provide this function the tripper needs to be controlled in such a way as to maintain the safety standards set out in AS1755. A list of specific tripper controls and switches is given below: Local Control Panel (LCP) Remote Control Panel (RCP) Tripper Position Switch (TPS) Tripper Travel Limit (TTL) Level Sensor (LS) 6.5.1
Local Control Panel
Much like a normal conveyor the tripper has a local control panel, however because the tripper is reversible it has an extended local control panel as mentioned previously. 6.5.2
Remote Control Panel
The remote control panel is not a standard feature for conveyors.
For specific
operational requirements Karara has requested that remote control be incorporated into the design of the tripper. This will allow the operators to move the tripper into position manually before discharging the minerals. The remote control system comprises of a remote control transmitter and a receiver. The receiver is connected to the digital inputs so that it may relay the required commands back to the PLC. The E/Stop is also hardwired from the remote control receiver into the
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hardwire circuit.
The remote control receiver does not have the local/auto selection
because that control is on the local control panel. When the remote is being used the local control panel 2-position switch will be set to local control and when it is not being used the tripper will function on auto.
Figure 2: Remote Control Panel Receiver
6.5.3
Tripper Position Sensor
In order for the tripper to position itself to discharge the minerals it uses a tripper position sensor. The reason for positional discharge is to prevent discharge of minerals onto the structural frame supporting the tripper. The tripper position sensor is a magnetic proximity sensor that is attached to the tripper. Metal flags are mounted to the conveyor so that the tripper position sensors send a signal when aligned with the flags. The tripper position flags are shown in drawing 1681EL-DRG-1283 in Appendix A – KIOP Electrical Drawings. 6.5.4
Tripper Travel Limit
The tripper travel limit is a protective stop control although not every tripper travel limit will stop the conveyor. The majority of the tripper travel limits are used as a signal of position to the PLC. This is required to convert any progressive position errors which would otherwise occur with the tripper position sensor system. The application of tripper travel Brad Smith – 30331929
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limits at each end is different because one end of the conveyor will have a service bay for the tripper and the other will not. For the Following sections please refer to drawing 1681-EL-DRG-1283 in Appendix A – KIOP Electrical Drawings. At the head end of the conveyor there are three tripper travel limits; one provides a signal that the tripper has entered the service area (TTL3), another to indicate the tripper is in position to be serviced (TTL2) and the final is a protective stop tripper travel limit to indicate that the tripper has travelled too far and should be stopped immediately (TTL1). TTL4 is located half way along the conveyor to indicate to the PLC when the tripper has passed the halfway mark of the conveyor. This is a precautionary measure that is used in conjunction with the tripper position sensor to confirm the trippers exact position. At the tail end of the conveyor TTL5 indicates to the PLC that the tripper has reached the end of the conveyor and that it should stop. If the tripper does not stop TTL6 will be tripped and will disengage the tripper. TTL1 and TTL6 are part of the hardwired circuit to physically stop the motor. 6.5.5
Ultrasonic Level Sensor
The ultrasonic level sensor (ULS) is used to measure the height of the minerals stockpile. Two ULS devices are attached to the tripper and communicate via Modbus back to the PLC. DeviceNet was considered but the length of cable is limited at the required data rate.
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Figure 3: Ultrasonic Level Sensor
6.5.6
Catenary Snag Sensor
The catenary snag switch is a sensor that indicates to the PLC that the catenary has been snagged while in motion. The Tripper will then be stopped to prevent any damage to the catenary or the cable running through it. The catenary snag sensor will be vendor supplied with the catenary.
6.6
Dust Suppression
AS1755 also covers the requirements of dust suppression around conveyors.
The
transfer points are of particular interest as this is where most dust is generated. Transfer points include conveyor to conveyor and tripper to stockpile.
The dust suppression
methods are different for each. 6.6.1
Dry Dust Controller
Dust suppression at the conveyor to conveyor transfer points consists of dust extraction fans that remove and collect the dust. The dust extraction fans may range from 30kW to 200kW in size depending on the area where extraction is required. The dust controllers have a local control panel and isolator much like the other equipment on the premises.
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6.6.2
Wet Dust Controller
Wet dust controllers are used at the tripper to limit the amount of dust created during material transfer. The following instruments and controls are used: Master Catenary Water Supply Solenoid (CSV) Dust Suppression Solenoid (DSS) Water Spray Sensor (WSS) 6.6.2.1
Master Catenary Water Supply Solenoid
The master catenary water supply solenoid controls the water supply to the tripper. In the event of a burst pipe the master catenary water supply solenoid will shut off the water. 6.6.2.2
Dust Suppression Solenoid
The dust suppression solenoid activates the water supply to the foggers that create a fine mist spray that is used to reduce the excess dust created by the material discharge. The tripper has two fogger sets, one on the front and one at the rear. 6.6.2.3
Water Spray Sensor
The Water spray sensor is a magnetic proximity sensor that is used in the same manner are the tripper position sensor. Flags indicate that the tripper has reached the position where the DSS needs to be turned off to prevent excess water collecting on the structural framework.
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7.0
Electrical Design
The electrical design team on the KIOP project is considered a supporting discipline; their role is to provide the necessary electrical design to complement the overall structural and mechanical design.
The mechanical department produces much of the information
required in electrical design. Good examples of this are the motor sizes required for the conveyors, where the mechanical department will size the motor and give that information to the electrical department to fill in the rest of the electrical design. Different areas of concern to the electrical engineers are: High Voltage Supply Transformer Low Voltage Distribution These aspects are discussed in the following sections.
7.1
High Voltage
The high voltage design consists of a feed from the Western Power incomer that connects to two transformers (each 2MVA). Power from these transformers will supply almost all of the stage 1 design. Conveyor CV702 will be the exception, due to the large distance between the transformers and the CV702 motor.
CV702 will be fed from
existing infrastructure. The transformer sizes were determined by the maximum demand calculation that estimates the total load on the electrical system.
The loads are determined by a
schedule that specifies what equipment will be active. The loads are then totalled so that the schedule will indicate which operating process will determine the maximum demand. Unfortunately, the intern played no part in designing the HV system although there was an opportunity to review the documents in order to become familiar with the project as a whole.
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7.2
Single Line Diagrams
The single line diagram provides a summary of all the electrical equipment that is connected to the motor control centres.
The large equipment have individual
connections whereas distribution boards (DB) feed the smaller equipment. The motor control centre (MCC) manufacturers generally use the information shown on the single line diagram as it indicates: the number of connections, busbar size, fault levels, cable sizes (to allow for proper termination) and circuit breaker sizes that are required. The intern was involved in many but not all of the aspects of the single line diagram design. The relevant aspects are listed below: Updating the single line diagram with load information Cable sizing Circuit breaker sizing Load balancing Aspects that were designed without the intern’s involvement are listed below: Busbar sizing Fault calculations The following sections discuss the intern’s involvement in designing the single line diagram. 7.2.1
Updating the Single Line Diagram
To update the single line diagram, the load information was retrieved and was marked up on the single line diagram; specifying the load type (motor or DB), current requirement and connection type from the MCC to the load. Refer to the drawings listed in Table 1: Single Line Drawing List in Appendix A – KIOP Electrical Drawings.
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Table 1: Single Line Drawing List
Drawing Number
1681-EL-DRG-1342 1681-EL-DRG-1343 1681-EL-DRG-1344 1681-EL-DRG-1345
Drawing Title
Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 1 of 4 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 2 of 4 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 3 of 4 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 4 of 4
The connection could be one of four types on KIOP: Variable speed drive (VSD) Direct online (DOL) Feeder Module (ELR) 7.2.1.1
VSD
A VSD is a method of controlling the power delivered to a motor and therefore controlling the motor. The VSDs used on KIOP are Telemecanique Altivar 71 devices that range from 2.2kW to 280kW. A VSD is used for its ability to ramp up the current upon starting to prevent large motor starting currents. The ability to reduce power output for stopping the motor is also an attractive function. A function that is not being used is that of precise speed control. There has been no encoder type feedback control mechanism provided, although it would be possible to incorporate this function in future upgrades. Upstream from the VSD is a circuit breaker that has a magnetic trip that is designed to protect against cable fault conditions. The circuit breaker is an Allen-Bradley 140M type and all technical information is taken from the Allen-Bradley website. 7.2.1.2
Direct Online
The DOL is a starting technique that applies either the full power, or no power. There are no ramp times. The DOL has an electronic overload (EOL) module that monitors the circuit and load integrity. The electronic overload is also connected to the PLC and is able to send signals reporting errors over Devicenet. The DOL can also be controlled via the electronic overload as shown in drawing 1681-EL-DRG-1696 in Appendix A – KIOP Electrical Drawings.
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The circuit breaker used for the DOL devices has a thermal and magnetic trip. This allows the circuit breaker to protect in a fault and in overload conditions. The circuit breaker is an Allen-Bradley 140UE type. 7.2.1.3
Feeder Module
The earth leakage relay uses a current transformer (CT) that measures the residual current across the active and neutral conductors. The ELR allows the current level and the time delay to be set, therefore reducing the need to size the cables for earth loop impedance (discussed in section 6.2.2). 7.2.2
Cable Sizing
Cable selection is based on 3 main criteria; current carrying capacity, voltage drop and short circuit conditions. AS3008 sets out the method of selecting cables by these criteria for cables below 1kV. AS3000 introduces an earth parameter, namely earth fault-loop impedance. As part of the internship, there was a need to create all the cable calculations for the single line diagram using the AS3008 and AS3000 standard design. The cable sizes are shown on the single line diagram listed in Table 1: Single Line Drawing List. Examples of the cable calculations are given in Appendix H – Cable Calculation Examples. The cable calculation sheet that was used, was created by the intern to make the tedious task of cable calculation quicker and to reduce errors in the calculations. The power of the calculation sheet comes from the calculations being executed by visual basic for applications (VBA). 7.2.2.1
Current Carrying Capacity
Selection of cables based on current takes into account the external conditions and the installation of the cables.
Focus is primarily on the thermal rating of the cable.
Depending on the type of installation, ambient temperature and number of circuits a derating factor is applied to the current required by the load. The derated current is then used to select the cable size.
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7.2.2.2
Voltage Drop
This section in AS3008 is a result of the AS3000 requirement that the voltage not drop more than 5% at the source of the low voltage supply, (i.e. from the transformer to the motor, the volt drop cannot be more than 5%). The voltage drop can be calculated using the AS3008 procedure of calculating the mV drop per A.meter and finding the corresponding table on standard cable volt drops. The volt drop can also be calculated using first principles V=I*R. 7.2.2.3
Short Circuit
The short circuit calculation determines the maximum allowable let through energyduring a fault. The cable should not be damaged due to the let through energy. The short circuit is based on the fault current and the time taken for the circuit breaker to trip. 7.2.2.4
Earth Fault-Loop Impedance
Earth fault-loop impedance is found in AS3000 and should be considered in the calculation of cable sizes. Essentially the larger the conductor the smaller the resistance and therefore the larger the current in the event of an earth fault. If the earth loop resistance is too large then the fault current will not be as large and may cause the circuit breaker not to trip quickly enough. The size of the conductors involved will determine the maximum earth loop length and therefore limit the total length from the source to the load. The calculation for the earth loop can be found in Annexure B of AS3000.
7.3
Switchroom
The switchroom houses the MCC, VSD panels and the PLC tier. The MCC has incomers from the transformers that connect to busbars that are used to connect to all the other equipment. As mentioned previously the MCC manufacturers will use the single line diagram to determine the requirements for the MCC panel. Refer to drawing 753940550402 in Appendix B – GPA Drawings The VSD panels house all the VSDs that are fed from the MCC and one rack for the associated PLC. Each VSD size plays a part in the design of the VSD panel as there are Brad Smith – 30331929
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standard modular racks and the VSDs are arranged to achieve the smallest possible VSD panel. It is also required that additional space is allowed for future expansions, normally 20% extra space. Internal to each rack are the VSD and associated equipment.
Refer to the general
arrangement drawing from GPA 7539405-50414 of the VSD rack from the GPA in Appendix B – GPA Drawings. 7.3.1
Schematic
The schematic diagram is produced to provide information about the VSD or DOL to the electrical installers and MCC switchboard manufacturers.
The intern was asked to
maintain, update and check the schematics. Below are the VSD and DOL schematics and the relevant points on each. Refer to drawing 1681-EL-DRG-1371 for the VSD schematic and 1681-EL-DRG-1696 for the DOL in Appendix A – KIOP Electrical Drawings. The right hand side of the schematic drawing shows a summary of the instrumentation that is associated with that piece of equipment. This part of the schematic is normally used when the PLC is being coded (discussed in section 6.4.3). 7.3.1.1
VSD Connections
The example of CV703 is used to show what is done when the conveyor has more than one associated VSD. The VSD operates in much the same manner except that one VSD is the master and the other the slave. This allows for the VSDs to work together with more efficiency. The information on the left hand side of the schematics shows: the incoming three phase active conductors, neutral and earth, circuit breaker, contactor, VSD or electronic overload device, isolator and then the connection to the load. The schematic also shows the connections available on the VSD/DOL device and where they are connected. The VSD is supplied with 24V DC from the 24V DC distribution single line. This 24V is used to power the indicator lights and small relays.
The 24V also connects to the
hardwire circuit that connects to: the local control panel E/Stop, ISO and the pull wire
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switch. Any additional hardwire requirements are wired in series to these devices. 24V DC is used, due to its safe operating voltage, for personnel safety. Once the drive has received the “get ready” command from the PLC relay R2 closes. This supplies power to K27 relay. Once K27 is active the secondary relay K27-1 closes which, provided the circuit breaker is closed, provides power to the K15 relay that closes the contactor supplying power to the VSD (K127 is the second motor relay, this would not normally be shown for a single VSD). At this stage the R1 relay is closed to indicate that the VSD is ready to start to output power to the motor. In the event of a fault the R1 relay will become de-activated. This will also deactivate the R2 relay because the R1 and R2 relays share a software variable and therefore are “interlocked”. K15 also has a secondary contact that is used as an input to the VSD to signal that the main contactor has been closed. The main circuit breaker also has a secondary auxiliary contact that is connected to an input into the VSD to confirm that there is power available to the VSD. While the motor is not running the motor heaters are active to prevent condensation. The K35-1 relay is a normally closed relay that draws power upstream from the VSD contactor. When the VSD is ready and starts to output power to the motor, relay LO4 is activated thereby indicating that the VSD drive is now running and simultaneously activating the K35 contactor to de-energise the motor heater (K135 is the second motor relay, this would not normally be shown for a single VSD). There are also motor temperature alarm and trip inputs (thermistor) to the VSD (TH1 and TH2). When the alarm thermistor is activated a signal is sent to the PLC to indicate the temperature. Then the trip thermistor is activated then the VSD will cease operation to prevent damage to the motor. At the bottom of the schematic the connection to Devicenet with a future connection to Modbus is available. The intern’s role in regards to the schematics was to become familiar with the VSDs by reading the VSD programming manual. This manual outlines the capable functions of the VSD.
Once familiar with the VSDs the intern then moved on to check all the
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schematics to ensure that they were correct and that the hardwire circuit was correct. A list of drawings that were checked and updated where necessary are given in Table 2: VSD Schematics Drawing List and can be found in Appendix A – KIOP Electrical Drawings. Table 2: VSD Schematics Drawing List
Drawing Number
1681-EL-DRG-1362 1681-EL-DRG-1363 1681-EL-DRG-1371 1681-EL-DRG-1372 1681-EL-DRG-1382 1681-EL-DRG-1383 1681-EL-DRG-1586 1681-EL-DRG-1392 1681-EL-DRG-1393 1681-EL-DRG-1401 1681-EL-DRG-1604 1681-EL-DRG-1402 1681-EL-DRG-1414 1681-EL-DRG-1415 1681-EL-DRG-1421 1681-EL-DRG-1422 1681-EL-DRG-1428 1681-EL-DRG-1429 1681-EL-DRG-1434 1681-EL-DRG-1435 1681-EL-DRG-1443 1681-EL-DRG-1444 1681-EL-DRG-1452 1681-EL-DRG-1453 1681-EL-DRG-1461 1681-EL-DRG-1462
7.3.1.2
Drawing Title
Conveyor CV702; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV702; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV703; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV703; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV704; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV704; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV704 Shuttle; Schematic Diagram - VSD Conveyor CV705; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV705; Schematic Diagram - VSD; Sheet 2 of 2 Tripper TP705; Schematic Diagram - VSD; Sheet 1 of 3 Tripper TP705; Schematic Diagram - VSD; Sheet 2 of 3 Tripper TP705; Schematic Diagram - VSD; Sheet 3 of 3 Belt Feeder BF517; Schematic Diagram - VSD; Sheet 1 of 2 Feeder BF517; Schematic Diagram - VSD; Sheet 2 of 2 Feeder FE518; Schematic Diagram - VSD; Sheet 1 of 2 Feeder FE518; Schematic Diagram - VSD; Sheet 2 of 2 Feeder FE519; Schematic Diagram - VSD; Sheet 1 of 2 Feeder FE519; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV520; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV520; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV521; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV521; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV522; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV522; Schematic Diagram - VSD; Sheet 2 of 2 Conveyor CV523; Schematic Diagram - VSD; Sheet 1 of 2 Conveyor CV523; Schematic Diagram - VSD; Sheet 2 of 2
DOL Connections
The direct online schematic is very similar to the VSD schematic, however instead of a VSD there is an electronic overload device. The power is supplied in much the same manner: through the circuit breaker, contactor, electronic overload, isolator and then the
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motor. The hardwire circuit is also the same, 24V supplied from the 24V distribution through the E/Stop and isolator. The “trip” relay internal to the direct online device will be normally closed and therefore when there is no fault the drive ready light will be active as well as supplying the “out-A” relay with 24V DC which is used to close the activate the relay K27 that activates the main contactor K16. Once K16 has been activated power will be supplied to the motor. The direct online device also uses the relay “out-B” to indicate a fault condition that will deactivate the “out-A” relay. The direct online device also takes three input signals that indicate: circuit breaker status, main contactor status and 24V supply status. There is also a connection to Devicenet. The intern’s duties with the DOL schematics was the same as the VSD schematics. A list of direct online schematics is given in Table 3: DOL Schematic Drawing List and can be found in Appendix A – KIOP Electrical Drawings. Table 3: DOL Schematic Drawing List
Drawing Number
1681-EL-DRG-1408 1681-EL-DRG-1410 1681-EL-DRG-1412 1681-EL-DRG-1696 1681-EL-DRG-1706
7.4
Drawing Title
Hematite Storage Shed; Ventilation Scrubber Unit 1 SB705A; Schematic Diagram - VSD Hematite Storage Shed; Ventilation Scrubber Unit 2 SB705B; Schematic Diagram - VSD Dust Collector - DC503; DOL Schematic Diagram Dust Collector - DC521; DOL Schematic Diagram Dust Collector - DC522; DOL Schematic Diagram
Instrumentation and Control Pack
The instrumentation and controls pack is made up of four parts; instrumentation and controls layouts, connection diagrams, hardwire drawings and the left hand side of the schematic. A list of example drawings are given in Table 4: Example of instrumentation and controls Pack Drawings from Appendix A – KIOP Electrical Drawings and will be used in the following sections.
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Table 4: Example of instrumentation and controls Pack Drawings
Drawing Number
1681-EL-DRG-1375 1681-EL-DRG-1376 1681-EL-DRG-1377 1681-EL-DRG-1378 1681-EL-DRG-1379 1681-EL-DRG-1380 1681-EL-DRG-1275 1681-EL-DRG-1276 1681-EL-DRG-1381
7.4.1
Drawing Title
Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV703-JBH; Digital Output Module; Connection Diagram Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV703-JBT; Digital Output Module; Connection Diagram Conveyor CV703; Instrumentation & Controls; General Arrangement Plan Conveyor CV703; Instrumentation & Controls; General Arrangement Elevation Conveyor CV703; Hardwired Connection Diagram
Instrumentation and Controls Layout
The instrumentation and controls layouts are created to provide the instrumentation installers with an overall view of the conveyor and its associated equipment. The layout also provides the approximate locations of the instrumentation, although the locations are not exact. Refer to drawings 1681-EL-DRG-1275 and 1681-EL-DRG-1276 in Appendix A – KIOP Electrical Drawings. In order to show the locations of the instrumentation two views are needed of the conveyor; plan and elevation. The plan and elevation are created by taking a “cut” of the 3D model. The 3D model is created by the structural and mechanical designers, who produce a scale model of the entire project. Once the drawings have been created the instrumentation can be added. In order to keep track of all the instruments for each conveyor a register was created. The register was then used to help populate the plan and elevation drawings. As well as to ensure sufficient inputs and outputs are available. The intern’s role in the instrumentation and controls layout was to populate all the instrumentation layouts. The intern was not required to become acquainted with the instrumentation nor provide a design. For example, the pull wire switches are required to be spaced 100m from the main device to an end support.
In some instances the
distance was decreased because the length to be covered was too long and therefore required more pull wire switches.
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The intern was also required to provide intelligent placement of the equipment so that the access way was not reduced to a width smaller than that allowed by the standard (600mm). Some conveyors only had personnel access to one side of the conveyor and therefore did not require a pull wire switch on the non-accessible side (AS1755). The drawings that populated in the intern, as part of the instrumentation and controls layout pack are listed below in Table 5: Instrumentation and Controls Drawing List Table 5: Instrumentation and Controls Drawing List
Drawing Number
1681-EL-DRG-1271 1681-EL-DRG-1272 1681-EL-DRG-1275 1681-EL-DRG-1276 1681-EL-DRG-1279 1681-EL-DRG-1280 1681-EL-DRG-1283 1681-EL-DRG-1284 1681-EL-DRG-1287 1681-EL-DRG-1288 1681-EL-DRG-1289 1681-EL-DRG-1292 1681-EL-DRG-1293 1681-EL-DRG-1296 1681-EL-DRG-1297 1681-EL-DRG-1317 1681-EL-DRG-1318 1681-EL-DRG-1325 1681-EL-DRG-1326 1681-EL-DRG-1329 1681-EL-DRG-1330 1681-EL-DRG-1333 1681-EL-DRG-1334
7.4.2
Drawing Title
Conveyor CV702; Instrumentation & Controls; General Arrangement Plan Conveyor CV702; Instrumentation & Controls; General Arrangement Elevation Conveyor CV703; Instrumentation & Controls; General Arrangement Plan Conveyor CV703; Instrumentation & Controls; General Arrangement Elevation Conveyor CV704; Instrumentation & Controls; General Arrangement Plan Conveyor CV704; Instrumentation & Controls; General Arrangement Elevation Conveyor CV705; Instrumentation & Controls; General Arrangement Plan Conveyor CV705; Instrumentation & Controls; General Arrangement Elevation Tripper TP705; Instrumentation & Controls; General Arrangement Belt Feeder BF517; Instrumentation & Controls; General Arrangement Plan Belt Feeder BF517; Instrumentation & Controls; General Arrangement Elevation Belt Feeder BF518; Instrumentation & Controls; General Arrangement Plan Belt Feeder BF518; Instrumentation & Controls; General Arrangement Elevation Belt Feeder BF519; Instrumentation & Controls; General Arrangement Plan Belt Feeder BF519; Instrumentation & Controls; General Arrangement Elevation Conveyor CV520; Instrumentation & Controls; General Arrangement Plan Conveyor CV520; Instrumentation & Controls; General Arrangement Elevation Conveyor CV521; Instrumentation & Controls; General Arrangement Plan Conveyor CV521; Instrumentation & Controls; General Arrangement Elevation Conveyor CV522; Instrumentation & Controls; General Arrangement Plan Conveyor CV522; Instrumentation & Controls; General Arrangement Elevation Conveyor CV523; Instrumentation & Controls; General Arrangement Plan Conveyor CV523; Instrumentation & Controls; General Arrangement Elevation
Connection diagram
The connection diagrams serve three purposes: show the contents of the junction box (JB), show the physical wiring of the equipment in the JB and assist the controls system integrators to tag all equipment so the communications network operates correctly.
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There are four types of connection diagrams currently used on KIOP, digital inputs, digital outputs, pulse counters and analog outputs. 7.4.2.1
Digital Input
The digital input diagrams generally have two drawings to show all the connections. This is because the digital input cards have 32 inputs and it is very difficult to fit 32 instruments onto one A3 page. Though the digital input diagrams are generally very similar, there are some exceptions. One such exception is that of the tripper. Because the conveyor and the tripper both have a JB, the emergency instrumentation from either is required to stop the other and vice versa. Refer to drawings 1681-EL-DRG-1403 and 1681-EL-DRG-1404 in Appendix A – KIOP Electrical Drawings. The digital input diagram is broken up into two parts, the junction box and the field. These sections are self explanatory but it should be noted that the digital input diagrams do not give any indication of required cable lengths. That information can be obtained from the instrumentation and controls layouts. At the top left of the diagram is the power supplied by the 240V distribution network. The 240V feeds a terminal strip, then a power supply converts the 240V into a 24V DC supply. The 24V DC supplies a terminal strip called “internal connections” which is used to supply the rest of the JB. Each 24V supply from the internal connection terminal strip has a small circuit breaker to isolate the faulty device to allow the rest of the JB to operate.
The “internal connections” terminal strip supplies power to the digital input
module (Allen-Bradley 1794-IB32), digital output module (1794-OB8EP), ControlNet adapter (1794-ACN15) and the terminal block DI. The terminal block DI has four separate power supplies to the terminal block DI, this is to prevent losing all the digital inputs if a fault occurs. This configuration will allow 24 inputs to remain if there is a fault on a single group of 8 inputs. At this point the digital input is the same for most of the conveyors. Devices that are unique to the tripper are the pull wire switch relay, remote control panel and the bypass relay.
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The pull wire switch relay has been added to comply with the safety requirements of AS1755. If there is an emergency and a pull wire switch is pulled then both the conveyor and the tripper need to stop. So the pull wire relay monitors both hard wire circuits and will trip both VSDs if either circuit is interrupted. This is evident on the tripper and CV705 schematic drawings 1681-EL-DRG-1392 and 1681-EL-DRG-1401 in Appendix A – KIOP Electrical Drawings. The bypass relay has been designed so that the inputs from the remote control receiver are not received when the conveyor is set to automatic control. This is to prevent any unintentional stops or disruptions to the conveyor. The bypass relay is controlled by the digital output module, which sets the status of the relay.
The relay then acts as a
gateway for digital input and digital output signals. The field side of the connection diagram has the symbols of the instruments that are connected in the field. The instruments are connected to the right hand side of the terminal block DI which is connected to the digital input module. In some cases the instruments are not shown on the diagram because they have connections to other modules. The remote control panel is an example of this, it is connected to the digital input but is shown on the digital output diagram. In this situation a reference is given to the appropriate drawing. 7.4.2.2
Digital Output
The digital output module has many of the characteristics of the digital input diagrams. The output module is supplied with power from the same power supply, has 8 outputs and sends digital output signals to a similar terminal strip. Refer to drawing 1681-ELDRG-1405 in Appendix A – KIOP Electrical Drawings. 7.4.2.3
Pulse counter
The pulse counter module is used for the belt feeders only. The other conveyors have an under-speed relay that signals the under speed, but the pulse counter reads the speed of the belt continuously. The power for the pulse counter is supplied from a separate power supply to prevent any interference from the other modules. Refer to drawing 1681-ELDRG-1419 in Appendix A – KIOP Electrical Drawings.
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7.4.2.4
Analog Output
The analog output is used to display the outloading rate of the conveyor system to the front end loaders. Each feeder is allocated a digital display unit that receives an analog signal from the analog output unit 1749-OF41. Refer to drawing 1681-EL-DRG-1448 in Appendix A – KIOP Electrical Drawings. 7.4.2.5
Internship Contribution
The intern was asked to become familiar with the above mentioned drawings and to populate the drawings with all the instruments for each conveyor. In some circumstance the quantity of instrumentation associated with a conveyor is minimal therefore there is wasted space in the JB. In these cases the instrumentation from one conveyor had been included on another connection diagram. This can be seen in drawing 1681-EL-DRG1448 in Appendix A – KIOP Electrical Drawings, that show the tail end instrumentation for CV521 and the head end instrumentation of CV520 in the same digital input drawings. As well as populating the instrumentation on the drawings, the intern was required to revise the electrical design of the connection diagrams to ensure that they met the design requirements given to Maunsell. A list of the connection diagram drawings is given in Table 6: Connection Diagram Drawings and the drawing are given in Appendix A – KIOP Electrical Drawings. Table 6: Connection Diagram Drawings
Drawing Number
1681-EL-DRG-1364 1681-EL-DRG-1365 1681-EL-DRG-1366 1681-EL-DRG-1367 1681-EL-DRG-1368 1681-EL-DRG-1369 1681-EL-DRG-1375 1681-EL-DRG-1376 1681-EL-DRG-1377 1681-EL-DRG-1378 1681-EL-DRG-1379 1681-EL-DRG-1380 1681-EL-DRG-1384 1681-EL-DRG-1385 Brad Smith – 30331929
Drawing Title
Junction Box CV702-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV702-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV702-JBH; Digital Output Module; Connection Diagram Junction Box CV702-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV702-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV702-JBT; Digital Output Module; Connection Diagram Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV703-JBH; Digital Output Module; Connection Diagram Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV703-JBT; Digital Output Module; Connection Diagram Junction Box CV704-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV704-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 39 of 70 22/04/2009
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1681-EL-DRG-1386 1681-EL-DRG-1394 1681-EL-DRG-1395 1681-EL-DRG-1396 1681-EL-DRG-1397 1681-EL-DRG-1398 1681-EL-DRG-1399 1681-EL-DRG-1403 1681-EL-DRG-1404 1681-EL-DRG-1405 1681-EL-DRG-1406 1681-EL-DRG-1416 1681-EL-DRG-1417 1681-EL-DRG-1418 1681-EL-DRG-1419 1681-EL-DRG-1423 1681-EL-DRG-1424 1681-EL-DRG-1425 1681-EL-DRG-1426 1681-EL-DRG-1625 1681-EL-DRG-1430 1681-EL-DRG-1431 1681-EL-DRG-1432 1681-EL-DRG-1433 1681-EL-DRG-1439 1681-EL-DRG-1440 1681-EL-DRG-1441 1681-EL-DRG-1445 1681-EL-DRG-1446 1681-EL-DRG-1447 1681-EL-DRG-1448 1681-EL-DRG-1449 1681-EL-DRG-1450 1681-EL-DRG-1457 1681-EL-DRG-1458 1681-EL-DRG-1459 1681-EL-DRG-1463 1681-EL-DRG-1464 1681-EL-DRG-1465 1681-EL-DRG-1466 1681-EL-DRG-1467 1681-EL-DRG-1468
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Junction Box CV704-JBT; Digital Output Module; Connection Diagram Junction Box CV705-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV705-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV705-JBH; Digital Output Module; Connection Diagram Junction Box CV705-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV705-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV705-JBT; Digital Output Module; Connection Diagram Junction Box TP705-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box TP705-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box TP705-JBH; Digital Output Module; Connection Diagram Junction Boxes TP705; Connection Hardwired Diagram Junction Box FE517-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box FE517-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box FE517-JBH; Digital Output Module; Connection Diagram Junction Box FE517-JBH; Pulse Counter Module; Connection Diagram Junction Box FE518-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box FE518-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box FE518-JBH; Digital Output Module; Connection Diagram Junction Box FE518-JBH; Pulse Counter Module; Connection Diagram Junction Box BF518-JBH; Analog Output Module; Connection Diagram Junction Box FE519-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box FE519-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box FE519-JBH; Digital Output Module; Connection Diagram Junction Box FE519-JBH; Pulse Counter Module; Connection Diagram Junction Box CV520-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV520-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV520-JBT; Digital Output Module; Connection Diagram Junction Box CV521-JBH; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV521-JBH; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV521-JBH; Digital Output Module; Connection Diagram Junction Box CV521-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV521-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV521-JBT; Digital Output Module; Connection Diagram Junction Box CV522-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV522-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV522-JBT; Digital Output Module; Connection Diagram Junction Box CV523-JBH; Digital Input Module; Connection Diagram - Sheet 1 of 2 Junction Box CV523-JBH; Digital Input Module; Connection Diagram - Sheet 2 of 2 Junction Box CV523-JBH; Digital Output Module; Connection Diagram Junction Box CV523-JBT; Digital Input Module; Connection Diagram Sheet 1 of 2 Junction Box CV523-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2 Junction Box CV523-JBT; Digital Output Module; Connection Diagram
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7.4.3
Schematic
The schematics also provide information about the instrumentation and controls pack. Each device will have associated instrumentation which is summarised in the right hand side of the schematic drawing. 7.4.3.1
Right Hand Side
The right side of the schematic shows the source, terminals, instrument symbol and then the digital input or output. This information is normally used by the PLC programmers so that the correct instrumentation is associated with the correct device. Almost all the information shown on the connection diagrams are shown in the schematic summary. Refer to drawing 1681-EL-DRG-1696 in Appendix A – KIOP Electrical Drawings. 7.4.3.2
Tripper
The tripper is slightly different because there is instrumentation on the tripper itself and therefore has a terminal box on the tripper to connect the instrumentation to the JB. Referring to drawing 1681-EL-DRG-1604 in Appendix A – KIOP Electrical Drawings. This schematic shows the summary of the instrumentation that is attached to the tripper physically. In order to run the cables to the tripper, the cables enter JB1 and then run along the catenary to JB2 then to the instrumentation and return through JB2 and JB1. 7.4.3.3
Internship Contribution
Once the connection diagrams were updated, the schematic instrumentation summary could be populated. The schematics were populated with all the instrumentation as listed in Table 2: VSD Schematics Drawing List. The tripper schematic 1681-EL-DRG-1604 was created using a previous project drawing as a template, which the intern modified it to suit the KIOP project.
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8.0
Lighting Design
The main priority for the lighting is to provide the required luminance to all working areas so that normal work, maintenance and repairs can be performed. The lighting should also provide safe egress from the buildings in the event of an emergency (AS1755). AS1755 refers to AS1680 Interior and Workplace Lighting to provide the benchmark for the lighting in and around conveyor systems. AS1680 is specific about the minimum level of light (lux) and the uniformity of the light required over an area to perform different tasks. Uniformity of light is defined as the ratio of the minimum lighting level and the average lighting level for a set surface area (AS1680.0, 1998). A summary of the main benchmark data used in the lighting design is given below in Table 7: Lighting Levels from AS1680. Table 7: Lighting Levels from AS1680
Minimum illuminance Minimum illuminance uniformity Minerals Handling
Conveyor gantries Transfer houses Switch room
20 lux 0.3
AS1680.0 AS1680.0
40 lux 80 lux 160 lux
AS1680.2.4 AS1680.2.4 AS1680.2.1
The intern was asked to produce the lighting design pack for KIOP stage 1. The lighting design for stage 1 includes internal and external lighting for: All conveyor gallery lighting The storage shed The MCC and transformer compound All transfer towers and take-up towers The first stage in the design process was to produce some computer simulated models that would give standard distribution of light fittings that would provide the required amount of light for safe functionality. The lighting modelling was done on a program called AGI32 and four models were produced as templates; switchroom, CV520, TT523
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and CV702 (standard conveyor gallery). General areas where lighting is required are discussed below.
8.1
Conveyor Galleries
The conveyor gallery, was simply modelled as a rectangular room with a rectangular column running horizontally to simulate the conveyor. The reason a solid column was used is that AS1680 calls for the lighting to be on access ways. Once the room and objects have been setup the light fixtures are added. This process was trial and error for the intern because there is little restriction on design laid down by AS1680 except the minimum requirement. First, the intern modelled the lighting with single tube fittings and it was found that the required spacing was quite close and the number of fixtures quite high. This was not desirable because the extra fittings would cost more money and because the time taken to install them would use extra man-hours (increasing cost). There was also opportunity to have too much light therefore more light fixtures than required, which required more cable to supply power. More power requires a bigger distribution board, larger quantity of cables, higher energy bills and ultimately cost more money.
Therefore meeting the
required standard will not only provide a safe working environment but also minimise costs. In order to reduce the number of light fixtures placed along the galleries a double fitting was used in the simulation. This provided a larger spacing between the light fixtures therefore requiring few fixtures and still met the requirements of AS1680. An advantage of the layout of the galleries is that the conveyor galleries are a standard design and therefore only require one model to determine the fixture spacing needed. Once the spacing is determined it can be applied to all the galleries. See Figure 4: Standard Conveyor Lighting Design Plan, Figure 5: Standard Conveyor Lighting Design Isometric and Figure 6: Standard Conveyor Lighting Design Rendered Model below of the lighting model for the conveyor galleries.
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Figure 4: Standard Conveyor Lighting Design Plan
Figure 5: Standard Conveyor Lighting Design Isometric
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Figure 6: Standard Conveyor Lighting Design Rendered Model
While most of the conveyors are very similar a few are different. In particular, conveyor CV520 does not have an enclosed gallery around it because it is located inside the shed. A factor that increases the complexity of design is the structural steel located to one side of the walk way, protruding from the walls. This poses a problem for wall mounted light as the steel will block the light from reaching all areas. The computer model does not of the whole conveyor but a section, in order to gather spacing information to be applied to the whole conveyor. During the design process Iit was discovered that some dark corners were created by the steel structures and this led to increasing the number of fixtures along the walls to provide the required lighting level. See Figure 7: Conveyor CV520 Lighting Design Plan, Figure 8: Conveyor CV520 Lighting Design Isometric and Figure 9: Conveyor CV520 Lighting Design Rendered Model below of the lighting model for conveyor CV520.
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Figure 7: Conveyor CV520 Lighting Design Plan
Figure 8: Conveyor CV520 Lighting Design Isometric
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Figure 9: Conveyor CV520 Lighting Design Rendered Model
8.2
Transfer Towers
The model for the transfer towers was produced after completing the conveyor gallery design and therefore progressed straight to the double fitting. The transfer towers are all different and therefore would require a separate model for each to model the lighting exactly.
However, while using the lighting simulator the intern was able to see the
lighting levels around the fixtures and use that information to design the lighting for the different transfer towers without running a simulated model for each. See TT523 Figure 10: Transfer Tower Lighting Design Plan, Figure 11: Transfer Tower Lighting Design Isometric and Figure 12: Transfer Tower Lighting Design Rendered Model below of the lighting model for the transfer tower.
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Figure 10: Transfer Tower Lighting Design Plan
Figure 11: Transfer Tower Lighting Design Isometric
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Figure 12: Transfer Tower Lighting Design Rendered Model
8.3
MCC and transformer compound
The lighting requirements for the switch room were much the same as the previous lighting designs but with an added requirement; that the lighting levels should be taken into account where the work would be conducted. In the case of the switch room, the lighting levels on the face of the MCC and VSD panels should be at the required lux level (AS1680). A similar design process to the transfer tower design was used for the switch room. Lighting for external areas of the shed and the transformer compound have been designed using a previous project (Mount Gibson Iron) drawings as templates.
See
Figure 13: Switchroom Lighting Design Plan, Figure 14: Switchroom Lighting Design Isometric and Figure 15: Switchroom Lighting Design Rendered Model below of the lighting model for the Switch room.
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Figure 13: Switchroom Lighting Design Plan
Figure 14: Switchroom Lighting Design Isometric
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Figure 15: Switchroom Lighting Design Rendered Model
8.4
Storage Shed
The internal lighting for the storage shed will be designed by the lighting contractor as part of the tender package.
8.5
Stairs and Handrail
The lighting design for the stairs and handrail has been taken from the MGI project. The design has been previously approved and therefore can be used for KIOP.
8.6
Emergency lighting
To comply with AS1755, emergency lighting needs to be provided to any persons within the structures in the event of an emergency in order for them to use a path to the exit of that building. The design will be taken from the MGI lighting design.
8.7
Design Results
The modelling of the different areas provided results listed in Table 8: Lighting Design Results.
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Table 8: Lighting Design Results
Area
Result of simulation In order to meet the requirements of AS1680 lights need to be
Switchroom
double globe XXX ceiling fixtures mounted parallel to the MCC/VSD panels.
Conveyor galleries
Single tube light fixtures mounted perpendicular to the conveyor at 5m spacing to provide the required light on the walkway. All lighting is to be double globe and wall mounted parallel to the
Conveyor CV520
conveyor. Spacing is to be XXX from the steel structure. Lights below access ways are to be ceiling mounted with similar spacing.
Transfer Towers
Lighting in the transfer towers is to be double globe and wall mounted in most cases spaced by approximately 4m Using MGI approved drawings, pole mounted lighting is to be
Stairs
placed at the top and bottom of stairs.
Handrail Mounts
All hand rail mountings to be single globe and spaced 3m. All pole mounted light fixtures at stairs are to be emergency. The general design theory is to make every second light fixture
Emergency lighting
(wall or ceiling) an emergency fixture. However descression is used in areas that are not standard areas.
Emergency exit
fixtures are also to be mounted in such a way that they indicate the closest exit.
8.8
Lighting and Small Power Drawings
Lighting drawings are produced to aid the lighting installers during installation.
The
drawings are not intended to be exact and therefore the installer requires the approval of the site superintendent before final locations are determined. The other component to these drawings is that the small power is included in the drawings.
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components include: general power outlets, welding outlets, three phase outlets, switch locations and more.
The Design requirements are given in Table 9: Power Design
Requirements and to see the symbols and descriptions please refer to the General Legend in Appendix A – KIOP Electrical Drawings. Table 9: Power Design Requirements
Equipment
Design Requirements
General Power Outlet (GPO)
The GPO’s will be spaced 60m. This limitation is in place to allow the use of a standard 30m extension cable. The welding outlets are to be located at both ends of conveyors
Welding Outlet
and anywhere else large 3-phase portable machinery is likely to be used.
Switched Outlet
The locations of the switched outlet are where more outlets may required.
Drawings are required for every location that will require a light fitting or small power. A complete list of drawing for stage 1 is given in Table 10: Lighting and Small Power Drawing List, and drawings can be found in Appendix A – KIOP Electrical Drawings: Table 10: Lighting and Small Power Drawing List
Drawing Number
Drawing Title
1600-EL-DRG-1076
General Legend; Lighting and Power
1681-EL-DRG-1246
Hematite Storage Shed; Internal & External Lighting; General Arrangement Plan
1681-EL-DRG-1247
Hematite Storage Shed; Internal & External Lighting; General Arrangement Elevation
1681-EL-DRG-1339
Switchroom SR-HEM Lighting, General Power & Communication; General Layout
1681-EL-DRG-1273
Conveyor CV702; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1274
Conveyor CV702; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1277
Conveyor CV703; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1278
Conveyor CV703; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1560
Take-Up Tower TU703; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1561
Take-Up Tower TU703; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1281
Conveyor CV704; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1282
Conveyor CV704; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1285
Conveyor CV705; Lighting & Power; General Arrangement Plan
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1681-EL-DRG-1286
Conveyor CV705; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1290
Belt Feeder BF517; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1291
Belt Feeder BF517; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1295
Belt Feeder BF518; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1294
Belt Feeder BF518; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1298
Belt Feeder BF519; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1299
Belt Feeder BF519; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1319
Conveyor CV520; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1320
Conveyor CV520; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1327
Conveyor CV521; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1328
Conveyor CV521; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1331
Conveyor CV522; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1332
Conveyor CV522; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1335
Conveyor CV523; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1336
Conveyor CV523; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1321
Tower TT503; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1716
Tower TT503; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1322
Transfer Tower TT521; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1725
Transfer Tower TT521; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1323
Transfer Tower TT522; Lighting & Power; General Arrangement Plan Sheet 1 of 2
1681-EL-DRG-1726
Transfer Tower TT522; Lighting & Power; General Arrangement Elevation
1681-EL-DRG-1728
Transfer Tower TT522; Lighting & Power; General Arrangement Plan Sheet 2 of 2
1681-EL-DRG-1324
Transfer Tower TT523; Lighting & Power; General Arrangement Plan
1681-EL-DRG-1727
Transfer Tower TT523; Lighting & Power; General Arrangement Elevation
In all cases the lighting general arrangement comes in pairs, a plan and an elevation. The plan view will show all the levels of the structure as a different section and this may lead to more than one plan drawing as in the case of transfer tower TT522.
The
elevations show a side view of the structure and may sometimes show the internal lighting and sometimes show only the external lighting. What is shown on the drawings is dependent on how cluttered they are because the drawings are not useful if they are not readable. A good example of this is transfer tower TT523 elevation. The intern’s role during the lighting design process was to firstly model the lighting to get nominal spacing for different areas. Then to advise the drafting department of all the “cuts” that were needed. The “cuts” are taken from the 3D model to show the relevant structures in the area where the lighting is to be installed. Once the cuts were returned, they were populated as per all the above mentioned drawings with the required lighting
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and small power. Once the pack (plan and elevation of each cut) markup was complete the drawings were returned to the drafting department to be drafted. The drawings were then returned for checking and when the intern was satisfied, the drawings progressed for approval to the electrical engineer.
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9.0
PLC Design
For safety and operational efficiency the Karara storage facilities will be controlled by a PLC. Automation generally provides time saving which leads to money saving. This PLC will be responsible for monitoring the field instruments for faults and operational conditions, sending signals to field instruments to indicate the diagnosed fault, startup and shutdown processes and communicating with the existing GPA port PLC. In order for the PLC to collect all the required data it will need to interface with multiple communication media: Ethernet, Devicenet, Modbus and ControlNet. The PLC will also be required to communicate with different areas of the GPA. For these reasons the same equipment will be used to allow minimal interfacing and commissioning complications as well as leveraging a commonality of spare parts. Equipment currently used by the GPA and MGI are in the Allen-Bradley industrial communications range. The PLC selected for KIOP is the Allen-Bradley 1756-PA72/C. This PLC was selected primarily for its large memory capacity and its strong performance capabilities. This allows Karara to upgrade and expand without upgrading the PLC. In the sections to follow, the different networks and general setup of the communications will be explored
9.1
Ethernet
All the port facilities PLC’s are connected to an Ethernet backbone communications network that passes status tags to each other to start and stop operational processes. This approach will be used for the Karara Iron Ore Project (KIOP) but will have a private network for Karara’s communications and have an interface between the private network and the GPA backbone network. The interface between the two networks will be through a firewall to minimise the security risks. This dual network approach will allow Karara to communicate with their equipment without adding traffic to the Ethernet backbone. A simple graphical representation of the network is shown below in Figure 16: Ethernet Network.
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Figure 16: Ethernet Network
9.2
Devicenet
Devicenet is the communications protocol used for communications between the PLC and the MCC and VSD panels. Devicenet was not the first choice for the communication medium but the selected VSD’s (Schneider Altivar 71) do not have the capability to communicate via ControlNet. Each unit contained in the MCC and VSD panels is connected to the PLC so that the PLC may send signals to start and stop devices such as the variable speed drives (VSD), soft starters (SS) or direct online drives (DOL).
The network also allows for status
information to be sent back to the PLC from the drives within the MCC. The primary function of this network is to control the start and stop sequences as well as controlling the running speed of the conveyors. In most cases the conveyors are run at a set speed (80% of capability) and seldom change their speed. There is one conveyor type that has a more active speed controller and that is the Feeder conveyor.
The Devicenet
communications will also be used in the event of an emergency to stop the conveyors.
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9.3
Modbus
Modbus has been is used on limited applications where specific equipment is required and communicates via Modbus. The two devices that currently use Modbus are the ultrasonic level sensors (ULS) and the Micrologic 6.0H power analysers. The Micrologic 6.0H is a sophisticated power analyser that can monitor frequency, power factor, circuit breakers and much more at the low voltage incomer level. This information is then sent back to the PLC.
9.4
ControlNet
All the field instruments require to be connected to the PLC in order for the PLC to gather all the relevant information to operate the storage facilities in a safe and efficient manner. ControlNet is specifically designed to be used in field instrument applications.
It is
capable of transferring information at high speeds and over long distances. Each conveyor’s junction box (generally two JB’s per conveyor) has a Flex I/O module that communicates with the PLC Flex I/O module. Each Flex I/O has a back plane that allows for different types of instrumentation modules to be connected. These modules include digital input, digital output, analog input, analog output, pulse counter modules and more. This allows for a very large variety of field instrumentation to be connected to the Flex I/O module that collects all the data and communicates back to the PLC via Controlnet. An example network is shown below in Figure 17: ControlNet Network.
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Figure 17: ControlNet Network
The devices shown in Figure 17: ControlNet Network are listed below (Allen-Bradley-A, 2004): 1756-PA72/C Allen-Bradley Processor 1794-ACN Allen-Bradley Flex I/O Module 1786-RPA Allen-Bradley Repeater Adapter 1786-RPCD Allen-Bradley Repeater Module In order for the ControlNet network to function correctly, it cannot have more than 121 s delay throughout the network.
Each device on the network provides a delay and
therefore the sum of these delays cannot be more than 121 s (Allen-Bradley-A, 2004). For example the 1786-RPCD repeater module has a delay time of 100ns, the 1786-RPA repeater adapter has a delay time of 901ns and fiber cable has a delay time of 5.01ns/m(Allen-Bradley-A, 2004).
9.5
Internship Contribution
During my internship I have been able to participate in the design of the communications network. Specifically, I have been involved in: Investigation of Network types and applications Investigation of equipment required Creation of the network block diagram (Appendix A – KIOP Electrical Drawings – 1681-EL-DRG-1353) Updating Schematics and Connection diagrams with communication network information
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10.0
References Allen-Bradley-A, (2004), ControlNet Fiber Media Planning and Installation Guide: 1786 Series, Rockwell Automation. AS1680, (1998) Interior Lighting: Safe Movement, Standards Australia AS1755, (2000), Conveyor – Safety Requirements: Third Edition, Standards: Australia AS3000, (2007), Wiring Rules: Fifth Edition, Standards Australia. AS3008, (1998), Electrical Installations – Selection of Cable: Third Edition, Standards Australia. Data sheets provided as appendices are also references
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11.0
Bibliography Merlin Gerin, (2006) LV Circuit Breakers and Switch Disconnectors: Compact NS, Schneider Electric. NHP, (2007) Price List Catalogue: Part B, NHP Electrical Engineering Specialists. Telemecanique, (2007) Variable Speed Drives: Altivar 71 Catalogue, Schneider Electric. Telemecanique, (2007) Variable Speed Drives: Altivar 71 Programming Manual, Schneider Electric. Toshiba, (2008) Premium Efficiency Electric Motors, Toshiba.
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