The project code 7304 was about complete retrofit of copper concentration plant by changing the technology.
The customer had ABB Advant Colibri system and increasing risk of system failure, cost of maintenance and obsoleted system function lead them to a modernization project.
We changed their system Technology from ABB to Siemens. PCS7 is modern cost effective solution for process controls with scalable architecture.
Siemens WIncc flexible design let us to customize new HMIs same as old ABB Colibri system and by utilizing high experience engineering team we manually translate and transferred logic from Advant DCS that was written in ABB obsoleted language AMPL to Siemen PCS7 for entire concentrate plant.
Properly derivation of information from existing system was a big challenge in this project. Throughout Copper crushing ore, Storage, Grinding, Floatation circuit, thickening and filtration, there were complicated process logic and vast variety of conveyors, pumps, agitators, mixer feeder that were interlocked together and they needed to be started and run in a group sequentially.
But aside to complicated process logic in the plant, writing a logic for Lifting heavy load mill in trunnion bearing, clutching, running and protecting mills needed high automation and process knowledge; In grinding area, at heart of this concentrate plant, there were a SAG mill at first stage and two ball mils,SAG (Semi-Autogenous Grinding) mill had key role in copper concentration plant and two synchrouse motors at two side of mill roll this heavy machine by a variable speed drive and writing logic for these sensitive machine needed advanced programing techniques.
By completing this project, the customer could use advantage of new DCS and plant production throughput improved and cost of maintenance and production deducted.