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1 New illustration is coming MINING USER CONFERENCE, MAY 3-5, 2017 Vale Itabira Case Operating and maintaining digital substations based on IEC Leandro Monaco, Global Product Manager Operations & Electrical Control System 800xA

2 Agenda of presentation Vale Company Overview What is IEC 61850? SAS Vale Itabira overview How does Vale Itabira SAS allows reduce Operational Expenditures (OPEX)? Protection and zone selectivity study Troubleshooting and root cause analysis Remote operation and monitoring Additional features that ensure reduced OPEX and ROI Benefits May 3-5, 2017 Slide 2, Stockholm

3 Vale Company overview Vale is a private-sector, publically traded company, headquartered in Brazil and present in around 30 countries Created by the Brazilian federal government on June 1 st 1942, with its operations restricted to the state of Minas Gerais. In its first year, it produced 40,000 tons of iron ore, the same amount it now ships out per hour. Privatized on May 6 th May 3-5, 2017 Slide 3, Stockholm

4 What is IEC 61850? Global standard for electrical substation automation and power distribution systems Based on 3 goals Interoperability Communication for protection & control between IEDs from different vendors Freedom of configuration The ability of each vendor to use different methods in the internal programming of the IEDs, as long as it obeys the goal of interoperability Long-term stability Ability of communication protocols to remain updated in front of technological advances May 8, 2017 Slide 4

5 SAS Vale Itabira overview Substation Automation System in numbers 3 Concentration Plants 21 Substations 02 Primary Substations of 230kV 02 Substations of 69kV 17 Substations of 13.8kV IED s 155 Users Tags 25 Servers 26 Workstations 21 HMI Panel First project delivered in 2010 May 8, 2017 Slide 5

6 How does Vale Itabira SAS allows reduce Operational Expenditures? Vale Itabira SAS Case Study IEC61850 Benefits Remote Problem Solving Faster Troubleshooting Safety for Staff Optimized Systems Connect substations Less maintenance Costs Energy efficiency & asset optimization Information readily available Reduces different technologies Vale Itabira cases Protection and zone selectivity study Troubleshooting and root cause analysis Remote operation and monitoring May 8, 2017 Slide 6

7 Protection and zone selectivity study How long and which activities would be required? Slide 7

8 Protection and zone selectivity study Electrical team only goes to substation when needed May 8, 2017 Slide 8

9 Protection and zone selectivity study Logic and parameterization a right-click away, saving time from maintenance team Slide 9

10 Protection and zone selectivity study Average time for surveying the protection parameters of the 18 IEDs into 2 substations Start time End time Description 10:00 10:01 Communicate with machine and enter access password 10:01 10:05 Opening PCM600 software within environment :05 10:07 Open the Substation Archive Base SE1215CN01 10:07 10:15 Communicate with relay UY1215CN501, choose the directory and save the settings 10:15 10:21 Time spent with directory difficulty (required to archive settings) 10:22 10:32 Communicate with relay UY1215CN502 to UY1215CN06, enter password and save settings 10:32 10:33 Close substation file SE1215CN01 10:33 10:34 Open the Substation Archive Base SE1475CN01 10:34 10:50 Communicate with relays UY1475CN501 to UY1475CN512 and save to mapped directory 10:51 10:52 Close Machine Total time for 2 substations and 18 IEDs: 52 min Slide 10

11 Protection and zone selectivity study Risk and activities eliminated Eliminated Risks Risks inherent to the displacement (approx. 6 km round trip) Exposure to the high voltage in substations (up to 13.8kV) Need to go up and down stairs Eliminated Activities No need to use of helmet, glasses, protection clothes No need to carry equipment such as laptops and network cables Fill in risk assessment form Slide 11

12 Troubleshooting and root cause analysis Overview from the entire electrical system in the control room Slide 12

13 Troubleshooting and root cause analysis Same information locally and remotely allowing faster and safer troubleshooting System overview Remote information about interlocks and protection x Slide 13

14 Troubleshooting and root cause analysis Same information locally and remotely allowing faster and safer troubleshooting Instant messages for every operation in power system Alarm & Event lists with time stamps from IEDs Slide 14

15 Troubleshooting and root cause analysis Automatic report generation Troubleshooting, root cause analysis and correction at the same day Slide 15

16 Remote operation and monitoring How to make sure that the users have the right knowledge? Slide 16

17 Remote operation and monitoring Avoid operation mistakes and leverage team knowledge even with low frequency of use Control, supervision, protection and measurement Slide 17

18 Remote operation and monitoring Internal trainings for electrical maintenance and operation teams Reduced the fear of the unknown and potentialized the benefits Slide 18

19 Information integration to ensure reduced OPEX and ROI Additional features CCTV Historian Condition Monitoring Energy Management Slide 19

20 Information integration to ensure reduced OPEX and ROI Additional features CCTV Historian Condition Monitoring Energy Management Slide 20

21 Information integration to ensure reduced OPEX and ROI Additional features CCTV Historian Condition Monitoring Energy Management Slide 21

22 Information integration to ensure reduced OPEX and ROI Additional features CCTV Historian Condition Monitoring Energy Management Slide 22

23 Benefits Operating and maintaining digital substations based on IEC Safer data collection Electrical data in real time and from a safe location Productivity Analyze each set of equipment: consumption per ton of ore Increased operating time Shorter maintenance shutdowns, reducing the risk of human failure Cheaper and safer Savings of 600 km of electric cables Simplified operation Change protection parameters via software and automatic system fault reports IEC61850 is present in almost every Vale plant in Brazil! Source: vale.com/brasil/en/aboutvale/news/pages/projeto-s11dutiliza-tecnologia-inovadora-automacao-subestacoes-eletricas.aspx Slide 23

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