SAFETY & HAZARDOUS AREAS GOING UNDERGROUND WITH INDUSTRY 4.0
of ignition. So, any devices of this type need to be equipped with explosion protection. On this evidence, it may seem as though
further adoption of Industry 4.0 in underground applications has hit an impasse. However, a technological breakthrough from Eaton may trigger the step-change that underground industrial applications need to move forward. The company has developed what is believed to be the world’s first fully integrated IP-based voice, data, WiFi, interlock and automation system for underground industrial applications where rugged and/or explosion-proof equipment is required. The system is known as SIMAS and it can use
How can the process sector extend automation and communication to protect people and plant operating underground? Christian Fimpler, product and program manager for Hazardous Area Communications at Eaton, has the answer
mining and minerals extraction. However, operating underground throws up some unique challenges that can inhibit the implementation of digitalisation. As a result, subterranean work environments are generally slower to adopt Industry 4.0 practices, limiting their ability to respond to changes in demand, adopt smart maintenance methods, or implement better safety regimes. The hazardous nature of underground
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environments such as tunnels and mines has resulted in a cautious approach to the introduction of technology. It is common for specialist standalone systems to be deployed, with safety-critical systems kept separate from automation and operational systems. Often developed by different OEM manufacturers, these systems have only limited options for connectivity and the exchange of information - particularly as they can use different program languages. For reasons of reliability, hard wiring is still
preferred over wireless systems for critical communications in underground installations. For example, each analogue telephone has its own cable, so if one experiences a fault the other devices are not affected. However, hardwired systems do have some drawbacks. Accommodating multiple cables in confined spaces is not easy: and while analogue
nderground working is common practice in many industries, from water treatment and chemical processing to
phones require one cable per device, digital/fibre optic cable and an IP structure can save space and cost. WIFI also encounters issues when being
applied underground. Electronic devices are known to be affected by dust ingress, high temperatures and interference - particularly from vibration and noise: none of which promote reliability. While robust design and IP- rated enclosures can do much to mitigate these effects, the risk that one electronic node failure could knock out communications to an entire sector is simply unacceptable in a hazardous working environment. Communications devices such as mobile
phones and tablets are not yet ubiquitous in underground locations. Quite aside from the connectivity issues, they are a potential source
data gathering via WIFI for non-critical applications, but still offers a safety circuit that is hardwired for the transference of critical data. This gives users the flexibility necessary to adapt to the challenges of working underground, while offering full integration of automation, communications and safety functions. Because it is designed as a fully integrated system by a single manufacturer, compatibility between the different functions is guaranteed, greatly improving reliability. System designers, project engineers and
end-users can choose to use any or all of the integrated functions that SIMAS offers – and its modular design makes it simple to alter or extend the system as demands change. Open interfaces mean it can also be used to link with third party systems as required. While SIMAS represents a major step
forward, Eaton’s hope is that it will be a springboard for further progress towards implementing Industry 4.0 underground. This could be on a practical level, such as finding ways of incorporating WIFI access points into lighting modules or metal roof supports to reduce installation time and space requirements. In the near future, Eaton expects to add addressable fire evacuation to this integrated system to enable phased evacuation of personnel, based on proximity to the hazard. Looking further ahead, the technology may
evolve to include ways of tracking each individual as well as each machine. This would enable the nearest available maintenance person to be notified to attend a fault, reducing downtime. Or, in the case of an emergency, it would help to plan rescue efforts because the exact position of the injured or ill person would be known: benefiting them and their rescuers. In conclusion, the improvement in
integration between automation and communication systems now offered by SIMAS is a major step forward, and as such should make a significant contribution to taking Industry 4.0 underground.
SIMAS should boost efforts to bring Industry 4.0 benefits to hazardous subterranean operations
Eaton
www.eaton.com
MAY 2021 | PROCESS & CONTROL 19
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