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Distribution Control System (DCS) Upgrade

In 2012, our Mining team set out to help an open pit copper mine located 125 kilometers east of Phoenix, Arizona. The condition of the mine was in question, so the client devised plans for extensive maintenance and troubleshooting efforts following the mine¡¯s last operating cycle.

We provided procurement, installation, and programming services for new Distribution Control System (DCS) hardware and software for the copper and molybdenum plant.

Confronting technical complexities, our team examined the operations equipment to find a DCS mix of modern programmable logic controller (PLC) hardware interspersed with 1970s hardwired relay logic. This hybrid is what required extensive maintenance and troubleshooting efforts during the mine¡¯s last operating cycle. Additionally, there were multiple types of PLC hardware and other areas of improvement that we addressed to increase the plant¡¯s overall power reliability.

Our specific services and scope of work items included engineering, panel procurement, area wiring changes, software review and modification, validation of programmable logic controller, and human machine interface (HMI) software.