Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
      • DesignSuite
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Instructor-led Courses
      • Training Workstations
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Virtuel Smart Machine Workshops
      • VirtualConnect: Smart Manufacturing
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • Media Contacts
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • EMEA Graduate Program
      • View All
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • DesignSuite
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Instructor-led Courses
  • Training Workstations
  • View All
  • View All
  • Blogs
  • Automation Today
  • Podcasts
  • Media Contacts
  • View All
  • View Jobs
  • EMEA Graduate Program
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Virtuel Smart Machine Workshops
  • VirtualConnect: Smart Manufacturing
  • View All
  • Live
  • On-Demand
  • View All
  • Digital Transformation at Norbord
  • View All
  • Brighter, More Flexible Tower Light Now Available from Rockwell Automation
  • Delphi Award Received For Asset Management
  • Internal Bypass Expands Smart Motor Functionality
  • New IaaS Bundle Eases Industrial Networking
  • Rockwell Automation Names Sebastien Grau as Regional Sales Director for Middle East, Turkey and Sub Saharan Africa
  • Expanded Power Range for PowerFlex 6000 MV Drives
  • Studio 5000 Software Update Optimizes Productivity
  • FLEX 5000 I/O Modules Bring Greater Productivity and Flexibility to a Connected Enterprise
  • New Cable-Pull Switch Enhances Industrial Safety
  • Instant Industrial Device Analytics
  • Rockwell Automation to name Al Ghandi Electrical & Automation as Authorised Distributor in the UAE
  • Rockwell Automation to Broaden Connected Enterprise Consulting Expertise with Acquisition of Kalypso
  • Single-Control Multi-Well Pad Solution Cuts Costs
  • Advanced Light Curtain System Improves Flexibility and Safety
  • Automation University
  • Rockwell Automation to Showcase the ConnectedProduction Solutions and Premieres its ThinManager Software at ADIPEC 2018
  • Safe Torque Off Option Simplifies Machine Design
  • Machine Performance Analytics Bring OEM Expertise Into Producer’s Digital Environment
  • Software-Powered Connected Services
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Rockwell Automation Simplifies Analytics for Industrial Productivity
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Securely Deploy Cloud and Mobile Technologies with New Network Guidance
  • Rockwell Automation drive system selected for Sumitomo Rubber’s rubber mixers
  • PlantPAx DCS Roadmap
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

AGL Loy Yang Upgrades Mine Conveyor

An innovative drive solution based on the PowerFlex 7000 medium voltage drive from Rockwell Automation helps streamline system upgrade

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • AGL Loy Yang required additional power to operate a longer conveyor system at the mine. To operate the extended conveyor an upgrade to the control system and drives were required

Solutions

  • Allen-Bradley® PowerFlex® 7000 medium voltage (MV) AC drives
  • Stainless steel cooled and removable drive enclosures
  • Allen-Bradley electronic operator interfaces
  • Replacement of ECC drives on some of the older conveyors

Results

  • Minimised production stoppages, breakdowns and unscheduled downtime
  • Advanced diagnostics and troubleshooting capabilities
  • Reduction in maintenance
  • Easy integration with existing drive systems and control architecture
  • Elimination of isolation transformers

Background

In Australia, coal-fired power generation is established as a valuable power source, providing vast quantities of inexpensive and reliable electricity. It accounts for approximately 75 per cent of the country's annual electricity production. Keeping Australia's coal-fired power generation infrastructure online – from the coal mine through to the generating plant and distribution grid – goes some way to ensuring the nation's industrial wheels remain turning.

As in all production processes, stoppages, breakdowns and unscheduled downtime can be crippling to the power generating process. Such outages can have a devastating effect, impacting both the energy producer's and end-users' bottom lines in a matter of minutes.

An energy industry stakeholder leading the way in providing industry with an uninterrupted supply of electricity is Victoria's largest energy producer is AGL Loy Yang. Located within the heart of the Latrobe Valley, 165 kilometres east of Melbourne, AGL Loy Yang provides reliable and efficient energy for industry and consumers right across south-eastern Australia.

As part of the company's ongoing commitment to producing reliable cost efficient energy, AGL Loy Yang has embarked on an upgrade of its four-level open-cut coal mine facility, Loy Yang Mine. The upgrade includes the redesign and progressive changeover of the mine's existing coal transfer conveyor drive systems. To obtain a drive solution capable of withstanding the rugged mine environment while delivering premium around-the-clock performance, AGL Loy Yang enlisted the engineering experience of Rockwell Automation.

Coal to Kilowatts

With an annual output of approximately 30 million tonnes of brown coal and four million cubic metres of overburden (soil that overlays the coal seams), AGL Loy Yang Mine is the largest coal-producing mine in the southern hemisphere. The mining process and the transportation of the coal from the bottom of the mine to the power stations is largely automated and features a range of sophisticated mining and materials handling technologies.

Huge electric-powered bucket-wheel dredgers, 50 metres high and 190 metres long, patrol the open-cut mine ‘benches', each excavating up to 4,000 tonnes of coal per hour on average. The bucket wheel of each dredger feeds on-board dredger conveyors, which in turn deposit the coal onto main transfer conveyor systems on each level of the mine.

Each transfer conveyor system comprises multiple separate conveyors, each with a belt-width of two metres and a travel speed of 5.2 metres/second (19 km/h). With a combined length in excess of 25kms, the mine's conveying system transfers the freshly mined coal from the mine floor to the surface. The transfer conveyor systems transfer the coal to a raw coal bunker, which has an 80,000-tonne capacity.

The coal is then transported directly from the bunker (also by conveyor) to two separate power stations located at the ‘mouth' of the mine. These are AGL Loy Yang's 2,210MW power station and GDF Suez's Loy Yang B 1,000MW power station.

Continuous Conveying

Providing a steady flow of coal feedstock to the coal bunker is essential to keeping the power generation process online and producing cost-effective electricity. As the coal bunker only has enough capacity to fuel 20 hours of power generation, the conveying system is under pressure to perform.

The legacy transfer conveyor drive systems at Loy Yang Mine were based on water-cooled eddy-current coupling (ECC) technology. When first installed many years ago, the ECCs were the ideal drive solution for providing high torque over a wide speed range – perfect for hauling enormous quantities of coal from the bottom of the mine to the surface.

However, it had become clear to the AGL Loy Yang Mine engineering team that the legacy drive systems were struggling to move the coal as efficiently as they believed was now possible. Furthermore, the existing Eddy Current Coupling drive systems were becoming increasingly difficult to maintain and the control systems unreliable.

“The ECCs are an older method of conveyor control and as the mine continued to grow we needed additional power so it was clear that we needed to move towards a more modern system,” said Robert Collins, electrical superintendent at AGL Loy Yang Mine.

“The need to keep up with increased power demand provided AGL Loy Yang with the opportunity to implement a drive solution incorporating the latest technology that would work effectively in the mine's rugged environment,” said Collins.

With the large number of conveyors on-site, AGL Loy Yang focused on implementing the drive technology in a gradual manner to enable integration with the existing drive systems and control architecture.

Compact, Contained and Cooled

In a collaborative effort, Rockwell Automation and the AGL Loy Yang engineering team developed a new drive solution, founded on the Allen-Bradley PowerFlex 7000 medium voltage (MV) AC drive. Featuring ‘Direct-to-Drive™' technology – a technology that helps eliminate the need for isolation transformers on applications with either new or existing motors – the Allen-Bradley PowerFlex 7000 MV AC drive provides space-efficient speed and torque control across a range of demanding drive applications.

The mine engineering team came up with an idea to equip each conveyor with a fully self-contained, cooled and removable drive package that could be easily installed or uninstalled on any of the mine's conveyors. This provides AGL Loy Yang with a level of portability that improves production flexibility.

According to Rockwell Automation engineering team leader, John Dunn, the compact nature of the PowerFlex 7000 drive simplified the development of the portable drive packages.

"The transformerless configuration of the PowerFlex 7000 meant we were able to help minimise the footprint of the drive package," he says. “The main electrical feature is the load sharing between different drives on each conveyor. We developed a partitioned stainless steel IP65-rated enclosure, equipped with an air-conditioned cooling system, to house each of the 6.6kV PowerFlex drives.”

The ‘minimal component count' was also a feature of the PowerFlex drive solution, with fewer parts eliminating the number of things that could go wrong.

Seamless Integration

Nine drive packages have been supplied to the Loy Yang Mine site to date. One of the main challenges throughout the upgrade has been integrating Rockwell Automation drive technology with the mine's existing drive technology and control architecture. The first PowerFlex 7000 drive packages interfaced with a PLC5 systems package in the neighbouring switchroom.

ControlLogix® is, in turn, linked to the mine's supervisory control and data acquisition (SCADA) system, via the mine's existing communications network. Each drive package is equipped with an Allen-Bradley electronic operator interface (EOI) located on the front panel of the drive enclosure.

“The drives can be interrogated via these EOIs or through the mine's SCADA system,” says Dunn. “The locally mounted EOIs make it easier for site personnel to access drive diagnostics without opening the dust-proof enclosures and exposing the drives to the elements.”

The Rockwell Automation and AGL Loy Yang engineering team developed a strategy that allowed the new drive packages to seamlessly synchronise with the existing ECC drives.

“Our long standing relationship with Rockwell Automation means integrating new drives at the mine has become a relatively straightforward project to complete. We have a lot of experience using the drives now, making it a fairly easy, run of the mill upgrade that doesn't take too long,” said Collins.

Proven Working Relationship

According to Dunn, “There were key benefits to the level of integration and flexibility achieved at the mine from being involved in this project from its inception and design phase, through to supply and installation.”

However, with upgrades at Loy Yang Mine continuing, there is much work ahead. The AGL Loy Yang team is planning to progressively replace other ECC drives across the mine. “When the first project with Rockwell Automation happened it was very significant for the mine, but our ongoing working relationship means that the drives have become very seamless to integrate,” says Collins.

AGL Loy Yang is currently in the process of constructing a new conveyor using PowerFlex drives inside a new switch room. Additionally, the engineering team is designing a new downhill conveyor based on the Rockwell Automation drive solution that will be used for backfilling the mine.

Published September 27, 2015

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left Denmark Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
  • Customer Experience Survey
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
Denmark/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
Denmark