Vale Canada Limited
Vale Canada Limited aimed to modernize the SAG Mill ancillary systems at its Clarabelle Mill due to aging electrical and control infrastructure.
The upgrade sought to enhance reliability, simplify diagnostics, and improve integration with the facility’s control architecture.
SCOPE
BESTECH was engaged for a comprehensive electrical and automation upgrade, which included replacing two motor control centres (MCCs) supporting all ancillary SAG Mill equipment. The new MCCs utilized Allen-Bradley electronic overload relays for advanced motor protection and real-time diagnostics. Obsolete GE PLC hardware was replaced with Allen-Bradley ControlLogix equipment, communicating via Ethernet/IP to remote I/O drops and devices.
Instrumentation integrated with the Foxboro DCS was migrated to the new PLC platform. BESTECH developed new HMI graphics using FactoryTalk View SE for centralized access to controls and diagnostics. The project encompassed PLC and HMI programming, configuration of relays, decommissioning of legacy signals, network integration, and commissioning.
OUTCOME
The upgraded system was successfully commissioned within the scheduled shutdown period, minimizing disruption to mill operations. The transition to modern Ethernet-based infrastructure significantly improved reliability and diagnostic capabilities, providing operators with better insights into equipment performance and reducing downtime. The project also laid a flexible foundation for future automation enhancements at the Clarabelle Mill.