Minas Demoproject en PDF

Application description 02/2014
PCS 7 in the mining industry

(Demo Project)
SIMATIC PCS 7, Minerals Automation Standard / CEMAT
http://support.automation.siemens.com/WW/view/en/81723640
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PCS 7 Demo Project (Mining)

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Table of contents
Table of contents
Warranty and liability ............................................................................................... 2
1 Overview ......................................................................................................... 4
2 Minerals Automation Standard / CEMAT ....................................................... 5
2.1 MinAS philosophy .............................................................................. 5
2.2 The advantages of MinAS.................................................................. 6
2.3 The operating methodology of MinAS ................................................ 7
2.4 Main features of MinAS...................................................................... 8
2.5 MinAS blocks................................................................................... 10
2.5.1 Drive functions................................................................................. 10
2.5.2 Control/monitoring ........................................................................... 11
3 Mining demo project..................................................................................... 12
3.1 Overview ......................................................................................... 12
3.2 Process screens .............................................................................. 14
3.3 Plant area: Crushing ........................................................................ 17
3.3.1 Primary crusher ............................................................................... 18
3.3.2 Operator controls for groups, routes and maintenance ..................... 19
3.3.3 Conveyor belts ................................................................................ 20
3.3.4 Stockpile.......................................................................................... 20
3.4 Operator controls ............................................................................. 21
3.4.1 Faceplates....................................................................................... 21
3.4.2 Object browser ................................................................................ 22
3.4.3 Integrated MinAS maintenance ........................................................ 23

3.4.4 Integrated MinAS trend .................................................................... 23
4 Installation and startup of the demo project ............................................... 24
4.1 Installing of MinAS ........................................................................... 24
4.2 Installing the demo project ............................................................... 25
4.3 Loading the AS program .................................................................. 25
4.4 Changing the computer name .......................................................... 26
4.5 Customizing the OS project ............................................................. 27
4.6 Launching the OS runtime ............................................................... 28
4.7 Initial state of the plant ..................................................................... 30
5 Operating the demo project ......................................................................... 33
5.1 Establishing the plant state using the object browser........................ 33
5.2 Performing fault diagnostics using "status call" and the object
list ................................................................................................... 36
5.3 Starting and stopping plant areas (groups) ....................................... 40
5.4 Faults in groups being started or already in operation ...................... 45
5.5 Integrated MinAS trend configuration ............................................... 49
5.6 Performing plant maintenance using the "maintenance list" .............. 51
5.7 MinAS alarm view with filter functions .............................................. 55
6 Further information ...................................................................................... 57
6.1 Application notes ............................................................................. 57
6.1.1 Process simulation .......................................................................... 57
6.1.2 Changing the operating mode .......................................................... 58
6.1.3 Storing notes on objects .................................................................. 59
6.2 Tips and tricks ................................................................................. 60
7 Sources and links ......................................................................................... 61
8 History .......................................................................................................... 61

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1 Overview
1 Overview
Application objective
This document provides you with an overview of the functional scope of the
Minerals Automation Standard (MinAS), as well as a description for the startup
and functional properties of the demo project.
Core contents of the application

The following key aspects are covered in this application:
Minerals Automation Standard / CEMAT
Installation and startup of the demo project
Operation of the demo project based on the example of typical operating
scenarios
Validity
The software requirements for operating the demo project are as follows:
SIMATIC PCS 7 V8.0 SP1 with a valid license or time-limited trial license.
Minerals Automation Standard / CEMAT V8.0 SP1 with a valid license or time-
limited demo mode.
You can find information about the product at:

Minerals Automation Standard / CEMAT
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Contact
cemat.industry@siemens.com

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2 Minerals Automation Standard / CEMAT

The Siemens Industry Automation division developed the Minerals Automation
Standard / CEMAT V8.0 to meet the special demands of the mining industry.
This standard uses the SIMATIC PCS 7 process control system, with its open,
flexible and scalable system architecture, as a system platform that is expanded
to include specific automation functions for mining applications.
The Minerals Automation Standard / CEMAT V8.0 (hereinafter abbreviated as
"MinAS") is a product for use in the mining and cement industry sectors.
Figure 2-1
2.1 MinAS philosophy

MinAS is more than just a library containing a few specific modules for the mining
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industry. It also represents a complete philosophy:

How are devices such as conveyor belts, crushers and grinders, or even the
entire process configured?
How are processes in the mining industry operated?
How can diagnostics be performed quickly and simply in order to keep
unplanned plant downtime at a minimum in the event of a fault?
As an integrated solution, the Minerals Automation Standard focuses on:

Efficient engineering and quality
Improved operation and monitoring

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2.2 The advantages of MinAS

Configuration
Many advantages are available to the plant engineer during process configuration:
A tested and well-documented library of software modules for functions in the
mining industry
Technology-oriented configuration to achieve the highest software quality,
even without programming knowledge
Standard interface between the software modules to minimize faults
Integrated simulation functions for engineering and factory acceptance tests
(FAT)
Bulk data processing
Operation
MinAS enables users to handle the system simply and intuitively thanks to:
Easy-to-understand symbols
Starting and stopping of entire process groups with a simple mouse click
Easy route selection

Efficient fault diagnostics
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2.3 The operating methodology of MinAS

The Minerals Automation Standard operating philosophy is, among other things,
based on different operating modes:
"Automatic"
"Manual"
"Local"
"Out of service"
Advantages for operations management can be seen for example in typical

applications such as system startup, troubleshooting (fault avoidance),
maintenance and the exclusion of devices.
The standardized and proven operating concepts result in reliable operation,
reinforced by the opportunity for standardized training.
Automatic mode
During normal operation, all drives in a technological plant area are started and
stopped in "automatic mode." The start or stop command is then triggered by the
start/stop sequence or by the configured process conditions.
Manual mode
In "manual mode", the drives can be started and stopped individually at the
operating station. The "manual mode" can be specifically activated or deactivated
for each individual drive or for groups.
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Local mode
In this operating mode, interlocks are only active to a limited extent. The application
areas for this operating mode are: startup, tests and maintenance work.
"Out of service" (maintenance)

The "out of service" mode prevents the drive from starting and disables all control
functions by locking the control output. It also disables all messages.
This operating mode is intended to be used with field devices that are defective
or undergoing maintenance work.

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2.4 Main features of MinAS

MinAS provides an extensive collection of preconfigured, tested and well
documented mining-specific library elements in order to offer support in various
different areas of application in the minerals industry (mining and cement).
To do this, it uses PCS 7 standard functions such as CFC configuration. For each
function block in the library, there is a block icon and accompanying faceplate with
a consistent look and feel. The icon and faceplate are automatically generated
for the graphical user interface and only arranged at the process screen in
combination with static graphic elements. These library elements and templates
reduce engineering time and improve engineering quality.
The essential functions are briefly described below:
Group control
Group elements enable the representation of a plant area's operating state and
provide detailed fault diagnostics for all related objects.
All drives, displays and measured value of a plant area are connected by a group
element. This group provides summary information about faults and alarms and
interrupts or prevents the starting procedure in the case of a fault.
Global object browser

The object browser provides a status overview of the objects present in the system.
Filter functions make it possible to search by operating mode, stored notes,
maintenance state or bypassed interlocks.
Object list
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The object list for a group shows the status of all related drives, measured values
and process signals. In addition, drives can also display their measured values
and process signals.
Information view
Additional information (links, documents, drawings, videos) can be linked to each
object. Information can be added during operation.
Integrated MinAS trend

Simple configuration of a trend display by selecting analog values at the process
screen during operation. The trend display can be saved and linked to a process
area.
Integrated MinAS maintenance

For drives and valves, additional information about maintenance and availability
can be configured. A maintenance view gives an overview of operating hours,
starts, stops with faults, and downtime.

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Diagnostics view
List of all relevant block inputs and outputs with the corresponding status There is
also the option to change some of the block parameters directly in the diagnostics
view.
MinAS alarm view

Up to 10 customized filters can be created for process messages. Filter types
include: plant area, measuring point, message type, message text, date...
In addition, "smart" filters make it possible to display alarms for active objects only.
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2.5 MinAS blocks

A detailed and complete description of the functions can be found in the product
description. All of the blocks from the SIMATIC PCS 7 standard libraries can also
be used.
The blocks relevant for this demonstration are listed below.
2.5.1 Drive functions
C_DRV_1D
The C_DRV_1D block is used to control drives with one direction.
C_DRV_2D
The C_DRV_2D block is used to control drives with two directions.
C_VALVE
The C_VALVE block is used to control valves.
C_SIMOS
The C_SIMOS SIMCODE adapter block connects CEMAT drive blocks with
SIMCODE.
C_ANNUN8
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At the C_ANNUN8 block, up to 7 binary process signals can be displayed. If one

of the process signals experiences a malfunction, then a fault or alarm message
is generated.
C_ANNUNC
At the C_ANNUNC block, one binary process signal can be displayed. If the
process signal experiences a malfunction, then a fault or alarm message is
generated.
C_MEASUR
The C_MEASUR block can be used to read analog process data and monitor up
to 8 limit values. It is possible to configure 4 of the limit values for the generation
of fault/alarm messages. The other 4 limits are switching limits and do not generate
any alarms.

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C_PROFB
The C_PROFB block can monitor binary or analog process feedback signals from
a drive, such as rotational speed or pressures.
If there is a fault in the process feedback, then the drive will be stopped via
a protective interlock.
2.5.2 Control/monitoring
C_GROUP
The C_GROUP block is a higher-level module used to switch technologically
related devices on and off in automatic mode.
The group block allows the visualization of operating states for a system section
in the form of a status display and detailed fault diagnostics (status call).
C_ROUTE
The C_ROUTE block is a module for selecting transport routes within a group.
C_SELECT
The C_SELECT block can be used for every type of selection function. In contrast
to the C_ROUTE block, it does not offer fault diagnostics.
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3 Mining demo project

3.1 Overview
The mining demo project illustrates the different process stages of a typical mining
plant and its plant hierarchy in the form of an overview.
In the process, the basic functionality and operation of MinAS are explained using
the example of the "primary crushing" plant section.
The MinAS demo project is divided into an AS section and an OS section.
AS section
In the "primary crushing" plant section of the AS program, the logic is configured for
a crusher, conveyor belts and dust collectors. The program contains blocks for the
acquisition of analog and digital data, blocks for controlling motors and valves, and
the blocks for route and group functions. If no process connection is available, the
signals and process data can be simulated with the help of a special test block.
Figure 3-1
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OS section
The demo project contains multiple process screens that are intended to clarify the
project using the example of a processing plant (e.g., for copper). In the "Crushing"
area, the function of a crusher, including the removal of the raw material
by conveyor belts, has been visualized. This plant area is configured for the
demonstration of MinAS. The remaining screens are static and do not have an
individual function.
Figure 3-2
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3.2 Process screens

Using the plant hierarchy, you can navigate between the overview, crushing,
grinding, rougher, cleaner, tailings and stockyard screens in the OS runtime.
These screens are briefly described in the following table:
Table 3-1
Description Screen
Overview
Here, you are given an overview of

the plant and can switch directly to
the desired plant section using the
buttons.
Crushing
(can be operated by user)
This plant section provides

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a visualization of a crusher and

the belts that remove the material.
After passing through the crusher,
the mined ore is fed to the next
process via two conveyor belts: one
for coarse material and one for fine
material. When the crusher is at
a standstill, ore can be fed to
the grinder from a stockpile.
This screen contains the
functionality of the demo project.
It will be discussed in greater detail
at a later point in this document.

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Description Screen
Grinding
The screen shows an example of an

overview for the grinding circuit.
The ore is first ground in an SAG
mill and is then ground in a ball
mill in a second stage.
Rougher
This part of the plant shows the first

stage of a flotation process,

which consists of a line of roughers
and an additional mill integrated in
the circuit.
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Cleaner
Here, the second flotation stage,

including a cleaning plant and
a filter press, is visualized.

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Description Screen
Tailings
The "Tailings" area is an example of

a screen for the recovery of process
water and removal of residual
stone.
Stockyard
This screen shows an example of

the loading of a product at a port.

The end product is delivered
by train, dumped into piles for
intermediate storage, and then
loaded onto ships.
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3.3 Plant area: Crushing

This process picture contains the functionality of the demo project. Here, you can
open faceplates, change the status of objects, select routes, start and stop groups,
etc. Detailed operation is explained in the chapter "5 Operating the demo project"
using different scenarios.
Figure 3-3
2
1
3
5
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(1) Primary crusher

(2) Control elements for the group start/stop, route selection, maintenance list
and the object browser
(3) Conveyor belt for feeding course ore to the secondary crusher
(4) Conveyor belt for feeding fine or to the grinder
(5) Stockpile

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3.3.1 Primary crusher
In the following partial image, you can see the crusher with the raw material hopper
and the subsequent screening.
Figure 3-4
3
(1) Signaling installation for adding more raw material

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(2) Fill level of the raw material hopper

(3) Drive for the crusher

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3.3.2 Operator controls for groups, routes and maintenance
Here, you can select routes and start or stop groups.
Figure 3-5
6
1
7
2
8
3
5
(1) Starts or stops the process of the selected route

(2) Route selection – crusher
(3) Route selection – stockpile
(4) Control of the water injection system on conveyor 1
(5) Control of the water injection system on conveyor 2
(6) Opens the object browser
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(7) Opens the maintenance list

(8) Opens the info dialog window

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3.3.3 Conveyor belts
Once crushing is complete, the coarse material is separated from the fine material.
The coarse material is transported to the secondary crusher via the first conveyor
belt. The finer material is taken directly to the grinder on the second conveyor belt.
Figure 3-6
1 2
(1) Dust collector 4

(2) Injection system
(3) Conveyor belt drive

(4) Safety switch for emergency stop and belt misalignment
3.3.4 Stockpile
Leftover material can be removed from the crusher and stored in a stockpile and,
if necessary, fed back into the process. You can define the source of the material
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feed using the route selection.
Figure 3-7
1 3
(1) Signaling installation for filling from the stockpile

(2) Fill level of the stockpile
(3) Conveyor belt drive

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3.4 Operator controls

3.4.1 Faceplates
The plant is operated using block icons and the related faceplates.
Figure 3-8
The design and functionality of the icons and faceplates of MinAS are based on
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the PCS 7 Advanced Process Library. By clicking on a block icon with the left
mouse button, you can open the related faceplate. Some icons, such as an analog
value measuring point, feature special functions that can be displayed by clicking
the right mouse button. The following views are available for all faceplates:
Standard
Diagnostics
Alarms and messages
Information
Presets for the PLC module (bits feature)
Additional views are available depending on the object, for example:

Object list
Curve view (trends)
Status call (groups and routes)

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3.4.2 Object browser
The object browser is a tool that can be used to apply filters for specific states of
the system objects throughout the entire OS project. You can thus display all of
the objects that have a particular status. You can select from the following options:
Interlock bypass
Message available
Power management active
Rapid stop
Service necessary
Object in "manual" mode
Object in "local" mode
Object in "out of service" mode
Object in simulation
The displays for the objects with the "manual," "local," "out of service" and
"simulation" modes can be combined.
Figure 3-9
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3.4.3 Integrated MinAS maintenance
Additional information can be used to configure drives and valves for preventive
maintenance. Here, a maintenance view or the object faceplates will provide
insight into the operating hours, starts, stops, stops with faults, and downtime.
Figure 3-10
3.4.4 Integrated MinAS trend

Every analog value that is saved to the Tag Logging archive can added to a special
trend display. Using the trend display, you can compare any number of desired
analog values with one another. You can configure the trend display by clicking
on the analog value icon item with the right mouse button. The trend groups can
be saved and reopened as desired.
Figure 3-11
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4 Installation and startup of the demo project
4 Installation and startup of the demo

project
4.1 Installing of MinAS
System requirements
Table 4-1
Hardware
AS PCS 7 CPU S7-414 or higher
ES/OS In compliance with the current PCS 7 specification
Table 4-2
Software
ES/OS SIMATIC PCS 7 V8.0 SP1
ES/OS Minerals Automation Standard / CEMAT V8.0 SP1
Installation
Installation of the MinAS required administrator rights. The target directory is
always"D:\CEMAT_CS". No other directory should be selected.
During installation, you will be asked to enter a project code. Enter the code "001"
for the Minerals Automation Standard. Additional project codes can be found in
the product's readme file.
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Figure 4-1

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4.2 Installing the demo project

If you haven't done so already, download the "MinAS_Demo.zip" file from the
Industry Online Support Site and copy the file to your Engineering System.
http://support.automation.siemens.com/WW/view/en/81723640
Table 4-3
No. Action
1. Open the SIMATIC Manager.
2. De-archive the demo project.
Select the menu command "File > Retrieve"
Navigate to the folder containing the "MinAS_Demo.zip" file and open the file.
3. Open the de-archived project.
4.3 Loading the AS program

The demo project is configured so that you can use PLCSIM as the automation
system. If you would like to load the program in a real automation system, you
may need to make adjustments to the hardware configuration and the WinCC
connection configuration.
Table 4-4
No. Action
1. Start PLCSIM
Start PLCSIM by clicking the "Simulation on/off" button in the SIMATIC Manager
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button bar.
Select the connection "PLCSIM(TCP/IP)". This switches the PC/PG interface to

"PLCSIM.TCPIP.1".
2. Load the configuration and the AS program in the simulator.
3. Set the status of the simulated CPU to "RUN" or "RUN-P".

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4.4 Changing the computer name

When you open the OS project, you will receive a message indicating that the
configured server is not available.
In order to start the OS runtime, you need to make a one-time change to the
computer name in the project. Proceed as follows:
Table 4-5
No. Action
1. Open the editor for the computer properties.
2. In the "General" tab, click the "Use Local Computer Name" button.
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3. To apply the new computer name, you must restart the OS project.
Close and then reopen the OS project.

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4.5 Customizing the OS project

If you would like to change the resolution of the OS project to match the screen
resolution of your monitor, you will need to follow a few steps. The PCS 7 standard
screens can be adjusted using the OS Project Editor. However, MinAS partially
uses its own screens, which are overwritten using PCS 7 standard screens when
the OS Project Editor is executed. In order to revert back to the typical MinAS user
interface, you will need to run the "CematProjectUpdate" tool.
Proceed as follows:
Table 4-6
No. Action
1. If you have not done so yet, open the OS project.
2. Open the OS Project Editor.
Select the necessary screen resolution.
Click the "OK" button.
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No. Action
3. Launch the "CematProjectUpdate" tool. You can find the tool in the MinAS
installation folder. "D:\CEMAT_CS\CematProjectUpdate.exe"
Select the target project. By default, the OS project last opened by WinCC is
shown here.
Select the screen resolution identical to the one in the OS Project Editor and
confirm you selection by clicking the "Res" button.
Execute the OS project update by clicking the "Update OS Project" button.
Once the update has been successfully completed, you can close the tool.
4. Generate the header file for C scripts.

Open the "Global Script C" editor.
Execute the "Generate new header" menu command.
4.6 Launching the OS runtime

When you launch the runtime, you will be asked to authenticate yourself with
a valid login.
Here, you will enter the login "Operator" and the password "123456".
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Figure 4-2

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Once you have successfully completed authentication, you can navigate between
the system sections using the area buttons.
Figure 4-3
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4.7 Initial state of the plant

Navigate to the "Crushing" plant area. This screen contains a concentrated
grouping of the demo project's functionalities.
Figure 4-4
When the AS program is restarted, the processing of material by the system is

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stopped. Simulation of the demo project is activated.

In chapter "6 Further information", you can find more useful information for
operation.
The system objects are in the following state:

Drives are off, and valves are closed and in both automatic mode and
simulation .
The emergency stop and misalignment switches are not active and are in
simulation .
No route is selected.
The group has not been started.
The signaling installations for filling the primary crusher and the stockpile are
"red."

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The system objects have the following appearance:
Figure 4-5
5
(1) Motor stopped
(2) Motor stopped with start interlock
(3) Valve closed
(4) Analog value display
(5) Digital display (misalignment switch with warning and alarm signal)
On some objects, a message is already configured. This is indicated by the

"memo" icon on the corresponding objects.
Figure 4-6
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In the control area for the group, the routes and the diagnostics, you will find the
following objects:
Group symbol for operating the plant section
Route symbol for selecting the material flow from the crusher
Route symbol for selecting the material flow from the stockpile
Symbol for the selection of the injection system on belt 1
Symbol for the selection of the injection system on belt 2
Figure 4-7
1
(1) The group is stopped and indicates that all connected objects are automatic
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mode .
(2) All routes are not deselected .

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5 Operating the demo project

The operation and functional properties of the demo project will be demonstrated
with the help of step-by-step instructions based on the following scenarios:
Establishing the system state using the object browser
Performing fault diagnostics before startup of the groups using "status call"
and the object list.
Starting and stopping plant areas (groups)
Faults in groups being started or already in operation
Integrated configuration of MinAS trends
Performing plant maintenance using the "maintenance list"
MinAS alarm view with filter functions
5.1 Establishing the plant state using the object browser

Scenario
In various situations, such as a shift change, it is necessary to quickly obtain
an overview of the complete plant state. The MinAS global object browser is
available as a powerful tool to help you achieve this. Filters allow you to quickly
achieve the desired information, for example: which objects had their status
changed to "out of service", which objects are in maintenance mode, or which
objects have a user note stored on them. From the list of results, you can quickly
switch to the faceplate of the desired object, where you can view detailed
information about the state of that particular object.
Conditions:
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The following conditions must be true for this scenario:

Some of the objects have an "out of service" status.
See chapter: "6.1.2 Changing the operating mode"
A note is already configured on some of the objects. By default, some of the
objects in the demo project already have notes.
However, if the notes have been deleted, you will find information about how
to restore them in chapter "6.1.3 Storing notes on objects".

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Operating steps
Proceed as follows:
Table 5-1
No. Action
1. Navigate to the "Crusher" plant section.
2. At the process screen, click on the "ObjectBrowser AS400" button to open the
dialog window.
3. Select the "Out of Service" option and confirm your selection by clicking the
adjacent button with the green check mark.
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No. Action
4. The list of results then displays all objects whose status is "out of service".
By double-clicking on a list entry, you can then open the faceplate of the desired
object.
Note
The entries are stored in the results list with a particular color. As can be seen in
the example, objects with the "out of service" status are highlighted in gray.
Objects with a "simulation" status are shown with an orange background.
5. Click the "Memo active" button in the object browser. The list of results then
displays all objects for which a note has been stored.
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6. Open the faceplate of an object by double-clicking its entry in the results list.
In the faceplate of the opened object, you can see in the status bar that there is
a message for this object.

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No. Action
7. Switch to the "Memo" view. Here, you can view the stored message.
5.2 Performing fault diagnostics using "status call" and

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the object list

Scenario
For the troubleshooting of assigned objects, MinAS offers efficient tools to
determine the status according to the hierarchical structure of a plant section.
In particular, these tools assist the user during the startup or stopping of plant
sections.
The "status call" is used for detailed fault diagnostics in order to display faults,
alarms and interlocks of the assigned measuring points, drives and valves.
This allows you to obtain a status from your system before starting it, even if the
objects have not yet triggered an alarm due to the fact that they are inactive.
This additional function reduces the amount of time necessary for fault diagnostics
and makes it possible to directly switch to the particular objects affected from the
list of results.
Conditions:
The group is stopped (system standstill).
Some of the objects have an "out of service" status.
An emergency stop (rope switch) or a belt misalignment switch (misalignment
switch) has been triggered. See chapter: "6.1.1 Process simulation"

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Operating steps
Proceed as follows:
Table 5-2
No. Action
1. You can already tell from the block icon that there is a fault in one of the group
objects. However, because the system is not in operation, no alarm has been sent
yet to the PCS 7 alarm logging system.
2. Open the faceplate for the route and switch to the "status call" view. Here, you can
see a preview of the message and react to the situation accordingly before starting
up the conveyor belts and triggering a real alarm.
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Entry-ID: 81723640, V1.0, 02/2014 37
No. Action
3. Switch to the "object list" view. Here, you will find all objects that belong to the
group. Search for the objects that have an "out of service" status. These are
highlighted in gray.
4. By double-clicking one of the objects, you can open the related faceplate.
Here, any notes that have been stored will indicate the reason for the status.
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No. Action
5. Change the status from "out of service" to "automatic" for all objects.
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5.3 Starting and stopping plant areas (groups)

Scenario
Technological process stages, such as the transport of material via conveyor belts,
flotation cells, or systems for grinding extracted ore, can be combined into groups
with MinAS. Operation and fault diagnostics are greatly simplified with the use of
groups. Grouped drives and valves can be set to a particular status in a parallel or
sequential manner with a simple mouse click. Fault conditions are displayed and
analyzed centrally in the group.
Conditions:
The objects are in automatic mode.
The group objects must be ready / there may not be any triggered alarms.
See chapter: "6.1.1 Process simulation"
Operating steps
Proceed as follows:
Table 5-3
No. Action
1. Select a route to start from within the group. To do this, open the faceplate for the
"Feed from Crusher" route. Click the "Sel." button to select this route.
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No. Action
2. Open the faceplate for the group and start the group by clicking the "Start" button.
Note
The startup of the group is indicated by the arrow in the group symbol.
3. The group startup passes through multiple phases.
1
2
3
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Phase 1: "Time for startup warning":

Length of time for the output of a signal indicating that the system is starting up.
Phase 2: "Waiting time":

Length of time between the alarm signal and the system startup.
Phase 3: "Startup release time":

The drives are started, valves are opened, etc. If any of the plant sections fail
to report operation once the startup time has expired, then a fault message is
displayed and the group is stopped again.
Note:
Operation of the group is indicated by the O in the group symbol.

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No. Action
4. In the plant process, the drives of the last conveyor belts are started first in order to
avoid an accumulation of material. The last thing to be started is the drive for the
crusher. Once the crusher is up and running, the signaling installation for ore filling
switches to green.
The block icon for the routes and the groups show the following status:
The "Start Feeding" is active.
The "Feed from Crusher" route is active.
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The "Feed from Stockpile" route is deselected and locked (interlock).

5. To switch the route, open the faceplate for the "Feed from Stockpile" route and click
the "Sel." button. In the block icon, the "P" indicates that this route has been
preselected.

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No. Action
6. Deselect the currently active "Feed from Crusher" route. Open the faceplate and
click the "Desel." button. Because the route is currently still locked (interlock), only
the color of the "S" icon changes from green to white. The "Feed from Crusher"
route is still active.
7. Start the group again to apply the route change.

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No. Action
8. Once the startup sequence is complete, the process screen will show that the
crusher and the 1st conveyor belt were shut down and that the conveyor belt from
the stockpile was activated instead. The signaling installation for the crusher
indicates that no more material may be added.
9. To stop the system again, open the faceplate for the group and click the "Stop"
button.
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Note
The shutdown of the group is indicated by the arrow in the group symbol.

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No. Action
10. Once the "shut down" process is complete, the system is once again in the original
state.
5.4 Faults in groups being started or already in operation

Scenario
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If a fault occurs during operation of a system, the affected plant section is stopped.
As a result, troubleshooting must be performed on the affected objects in order to
solve the problem. MinAS provides different functions that help the user keep
downtime as short as possible during troubleshooting.
Together with the information view, the object list offers information about the
status and process signals for all of the objects in a group.
Conditions:
The group is active or currently starting up.
See chapter: "5.3 Starting and stopping plant areas (groups)"
An emergency stop signal (e.g., RS_BC01_S4701) has been triggered.
Figure 5-1

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Operating steps
Proceed as follows:
Table 5-4
No. Action
1. An emergency stop was triggered in the area of the first conveyor belt, causing an
alarm to be triggered by the PCS 7 alarm logging system and to be displayed in the
alarm line of the runtime interface. The block icons for the route and the group are
marked with an alarm icon. As a result of the alarm, the drive of the first conveyor
belt was stopped and locked to prevent a restart.
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2. To determine the cause of the alarm, open the faceplate for the group and switch
to the "object list" view. The red symbols in the list mark the object that triggered
the system stop.

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No. Action
3. By double-clicking the list entry, you can open the related faceplate and use it to
obtain detailed information.
4. Use the simulator block to reset the emergency stop signal again.
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5. Before you can restart the faulty conveyor belt, you must acknowledge the current
fault and reset the conveyor belt drive again.
You can acknowledge the fault using the acknowledgment button next to the PCS 7
alarm line, in the PCS 7 alarm view or in the CEMAT alarm view.

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No. Action
6. The current fault on the drive can be reset in the faceplate. To do this, click the
"Fault reset" button.
7. Start the group again by opening the faceplate and clicking the "Start" button.
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5.5 Integrated MinAS trend configuration

Scenario
With the trend-configuration option integrated in MinAS, you can configure
customized groups of trends and save them to be displayed again as desired.
Trends provide the user with information about the operating state of the plant
or the performance of individual components.
You can easily active the trend configuration directly from the process screen by
selecting the desire measuring values.
Conditions:
No particular conditions are necessary for this scenario.
Operating steps
Proceed as follows:
Table 5-5
No. Action
1. To access the trend group configuration dialog, click the unit of the desired analog
value with the right mouse button. You can also add other values by right-clicking
on the unit of the analog measuring point. The trend configuration dialog window will
remain open during this step.
Add the following analog values to the trend configuration:
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(1) Material flow for conveyor belt 1

(2) Material flow for conveyor belt 2
(3) Raw material fill level

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No. Action
2. At the configuration dialog window for the trends, you can see the analog values
selected, administer the groups and call the trend display.
3
1
(1) Selected analog values

(2) Saved trend configurations

(3) Button for calling the trend display
3. The trend display shows the tag values in different colors. The display can be
switched between current values and values from the archive.
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1 2
3 4
(1) Online tags

(2) Archived tags
(3) Button for navigating through archived values
(4) Button for displaying current values

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5.6 Performing plant maintenance using the "maintenance

list"
Scenario
For drives and valves, MinAS offers additional information concerning preventive
maintenance and availability. Here, an MinAS maintenance view or the object
faceplates will provide insight into the operating hours, starts, stops, stops with
faults, and downtime.
The drives and valves can be configured using the following maintenance settings:
Fixed maintenance interval
Maintenance after predetermined number of operating hours
Maintenance after specific number of starts (motor) or openings and closings
(valve).
This allows you to create statistics, e.g. for operating hours, stops or downtime
due to faults. In addition, the maintenance information can be used to derive
maintenance alarms or be made available to other external maintenance systems
in the block.
Conditions:
No particular conditions are necessary for this scenario.
Operating steps
Proceed as follows:
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Table 5-6
No. Action
1. Configure a service interval for a few motors and valves and start the maintenance
service. To do this, open the faceplate for a motor or a valve and switch to the
"maintenance" view. The button is located on the second level of the view buttons.
This level can be activated by clicking the "..." button.
2
(1) Select the type of maintenance interval and configure the time or the number
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of starts.
(2) Here, you can configure the time or the number of starts that will result in
maintenance being demanded.
(3) You can activate the maintenance function by clicking the "Start" button.

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No. Action
2. A maintenance demanded notification is indicated by the wrench icon . Detailed
information can be found in the faceplate of the object requiring maintenance.
2
3
4
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(1) Maintenance status of the object

(2) Maintenance service status
(3) Maintenance personnel status (manual maintenance)
(4) Button for resetting the maintenance function

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No. Action
3. You can obtain an overall status for all objects that have a configured maintenance
function using the "CEMAT Maintenance List." You can open the overview in the
demo project by clicking the "Maintenance List" button.
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5.7 MinAS alarm view with filter functions

Scenario
The messages and alarms in the system remain a crucial source of information for
determining the system operating mode. The analysis of these alarms also enables
you to draw conclusions about unexpected behavior from plant sections or their
components. For these tasks, MinAS offers the user an advanced alarm view with
special functions that can be saved. The advanced alarm view is simple to handle
and is used to provide selective information about the location and type of fault.
Conditions:
At least one object has triggered an alarm in the PCS 7 alarm logging system.
For this to be possible, the group must already be started when a fault occurs.
Operating steps
Proceed as follows:
Table 5-7
No. Action
1. Click the button for the MinAS alarm view in the PCS 7 OS button menu.
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2. Using the area buttons, you can show or hide the display for messages from the
corresponding plant area.

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No. Action
3. Additional filter settings are available if you switch the alarm view to the long-term
archive.
1
2 3 4
(1) Switch between the current and long-term archives; close the alarm view
(2) Refresh the filter settings
(3) Saving and loading filter settings
(4) Additional filter settings for event, message tag, and message class
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6 Further information
6.1 Application notes
6.1.1 Process simulation
In order to enable useful application despite a lack of connected hardware,

a simulation was integrated. The simulator block allows the simulation of fault
conditions, such as a misalignment of the belt, a triggered emergency stop, or
a defective drive.
You can activate or deactivate the simulation by clicking the "SimOn" button in the
"Crushing" plant area. The hand icon opens the block for the simulated process
signals.
Figure 6-1
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At the opened faceplate, you can switch the binary signals on or off and adjust
the analog values for the fill levels and the material flow using the slider.
To make it easier to locate the measuring point names, the following prefixes were
added:
Drv: drive
Vlv: valve
RS: rope switch (emergency stop switch)
MS: misalignment switch
6.1.2 Changing the operating mode
To change the operating mode of a motor, a valve or a measuring point, proceed

as follows:
Figure 6-2
1
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(1) Open the faceplate for an object.

(2) Click the button for changing the operating mode.
(3) Select the new mode, e.g. "out of service."

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6.1.3 Storing notes on objects
You can store notes on the objects in the project. With the object browser, it is easy
to find all of the objects that have a note. To add a note to an object, proceed as
follows:
Figure 6-3
1
4
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(1) Open the faceplate for an object.

(2) Switch to the "memo" view.
(3) The "Note" tab contains a text field in which you can leave your message.
(4) Save the text you have entered.
Once you have completed this, a note icon is displayed in the faceplate header.

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6.2 Tips and tricks

Trend groups
There are different ways to operate the MinAS block icons for analog value
acquisition. The following possibilities are available to you:
Left mouse click:
The faceplate for the selected analog value is opened.
Right mouse click on the analog value:
A trend display is opened which shows the archived value with the limit values
that are currently set.
Right mouse click on the unit of the analog value:
The configuration dialog window is opened for the MinAS trend display.
Adjusting the OS screen resolution

The standard PCS 7 tool for adjusting the screen resolution is the OS Project
Editor. However, the Project Editor also replaces the special MinAS screens.
To revert back to the normal MinAS interface after changing the resolution, you
can use the "CematProjectUpdate" tool.
Perform the steps illustrated in chapter "4.5 Customizing the OS project."
Displaying the measuring point names

To display the measuring point names at the process screen, you can use the
function integrated in MinAS. To do this, click the following button:
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Figure 6-4

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7 Sources and links
7 Sources and links

Table 7-1
Subject field Title
\1\ Siemens Industry http://support.automation.siemens.com
Online Support
\2\ Application page for http://support.automation.siemens.com/WW/view/en/81723640
this entry
\3\ Minerals Automation http://www.siemens.com/minas
Standard
\4\ Mining at Industry http://support.automation.siemens.com/WW/view/en/63697570/136
Online Support 000
8 History
Table 8-1
Version Date Change
V1.0 11/2013 Publication

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Entry-ID: 81723640, V1.0, 02/2014 61

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Application description 02/2014

PCS 7 in the mining industry

Warranty and liability

body or health, guarantee for the quality of a product, fraudulent concealment of a

Any form of duplication or distribution of these Application Examples or excerpts

PCS 7 Demo Project (Mining)

3.4.3 Integrated MinAS maintenance ........................................................ 23

PCS 7 Demo Project (Mining)

Core contents of the application

You can find information about the product at:

PCS 7 Demo Project (Mining)

2 Minerals Automation Standard / CEMAT

2.1 MinAS philosophy

industry. It also represents a complete philosophy:

As an integrated solution, the Minerals Automation Standard focuses on:

PCS 7 Demo Project (Mining)

2.2 The advantages of MinAS

Easy route selection

PCS 7 Demo Project (Mining)

2.3 The operating methodology of MinAS

Advantages for operations management can be seen for example in typical

"Out of service" (maintenance)

PCS 7 Demo Project (Mining)

2.4 Main features of MinAS

Global object browser

Integrated MinAS trend

Integrated MinAS maintenance

PCS 7 Demo Project (Mining)

MinAS alarm view

PCS 7 Demo Project (Mining)

2.5 MinAS blocks

2.5.1 Drive functions

At the C_ANNUN8 block, up to 7 binary process signals can be displayed. If one

PCS 7 Demo Project (Mining)

PCS 7 Demo Project (Mining)

3 Mining demo project

PCS 7 Demo Project (Mining)

PCS 7 Demo Project (Mining)

3.2 Process screens

Here, you are given an overview of

This plant section provides

a visualization of a crusher and

PCS 7 Demo Project (Mining)

The screen shows an example of an

This part of the plant shows the first

stage of a flotation process,

Here, the second flotation stage,

PCS 7 Demo Project (Mining)

The "Tailings" area is an example of

This screen shows an example of

the loading of a product at a port.

PCS 7 Demo Project (Mining)

3.3 Plant area: Crushing

(1) Primary crusher

PCS 7 Demo Project (Mining)

3.3.1 Primary crusher

(1) Signaling installation for adding more raw material

(2) Fill level of the raw material hopper

PCS 7 Demo Project (Mining)