Vale Canada Limited
Vale faced challenges with the aging PLCs that controlled the ore handling muck circuit at their facility.
These PLCs were at the end of their service life and did not align with the new Modicon M580 PLC platform that had been adopted across other parts of the mine. The upgrade was crucial to ensure reliability, enhance control, and maintain compatibility with the mine’s broader technological infrastructure.
SCOPE
The project identified the 2600L and 3935L rock breaker PLCs, along with the 3935L Crusher PLC, as critical components needing upgrades. The existing control system was not only outdated but also lacked comprehensive and accurate documentation, which posed significant challenges for ongoing maintenance and future upgrades. To address these issues, new remote controls were installed to allow for the operation of the rock breakers from the surface, thereby improving operational safety and efficiency.
A thorough site investigation was conducted to update and correct the existing drawings for all three PLCs. For some systems where drawings were non-existent, new as-built drawings were created. This process involved meticulous documentation to ensure all modifications and current configurations were accurately captured. Additionally, new construction packages were developed for each of the PLCs, which included detailed schematics and guidelines for installation and future maintenance.
OUTCOME
The upgrade project successfully standardized the PLC designs across the mine, aligning them with Vale’s site-wide standards for design, hardware, and equipment identification. This standardization facilitated easier maintenance and scalability of the system.