Glencore Sudbury INO
This project aimed to enhance safety and productivity at Glencore’s Smelter by upgrading converter controls in phases, permitting one converter upgrade at a time to limit production impact.
The focus was on modernizing control systems, starting with the Number 5 (N5) Converter, followed by the Number 6 (N6) Converter, to create a safer operational environment.
SCOPE
The first phase upgraded the N5 Converter, relocating controls to a new environmental control booth to enable remote operation and reduce operator exposure to hazards. The upgrade involved additional instrumentation, communication, and monitoring hardware. Enhanced video surveillance, including infrared capabilities, improved safety in the converter aisle. The N5 controls were integrated into an ergonomic console with pushbuttons, lights, a joystick, video monitors, and control screens. The relay panel was redesigned for remote control, replacing two GE relays with Allen Bradley relays and adding seven new units with a new power supply.
The second phase mirrored these enhancements for the N6 Converter to ensure consistency.
OUTCOME
These upgrades improved safety by reducing personnel exposure to hazards and boosted productivity. Centralized control systems allowed for better management of converters. The ergonomic control consoles improved operator comfort and reduced fatigue, enhancing performance and safety. The project’s success paved the way for similar upgrades in other areas across the site.