- Increase employee safety
- Reduce arc flash hazards
- Minimize equipment risk
- Unreliable, aging equipment
- Outdated technology
- Limited data
- Allen-Bradley® CENTERLINE® 2100 Motor Control Centers (MCCs) with ArcShield™ technology
- IntelliCENTER® technology
- Significant CAL Rating reduction
- Increased data & performance analytics
- Remote access
- Space saving design
- Ease of installation
As part of a large-scale initiative, a global mining company is upgrading the power, automation and controls, including replacing the low voltage (LV) motor control centers (MCCs), at one of its Canadian milling sites. This location processes and refines ore from the company’s local mines into a nickel-copper concentrate.
Challenge
Aging equipment increases risk to personnel and process
“Not only do we want to modernize the technology, but we want to make it safer for the employees that interact with the equipment,” said an automation specialist with the company. “Safety is at the forefront of everything that we do.”
After conducting a risk analysis of its existing MCCs, the mill identified nearly 60 that were deemed a risk due to a combination of equipment age, safety and process criticality.
“The risk on legacy gear is inherently higher because it wasn’t designed to meet today’s safety requirements, especially for arc flash” explained Curtis Tulloch, operations manager with Walden Electrical, the mining company’s longtime Canadian electrical contractor.
An arc flash is the result of a discharge of electrical energy that can produce high temperatures, bright flashes of light, and loud sounds, and can inflict serious injuries including burns, damaged hearing, and impaired eyesight.
“Arc flash can harm personnel and damage the MCC and surrounding equipment,” Tulloch said. “If you take out one of these older MCCs, you’re taking out the entire process and impacting the operation for a significant amount of time.”
The mill ranked each of the identified MCCs by risk from highest to lowest to determine their replacement schedule. They started with two LVMCC lineups that were installed by a previous vendor in the early 1970s. These MCCs help run the mill’s various pumps, fans, conveyor belts, and other equipment.
“Our goals were to increase safety, increase reliability and have the data and analytics — a capability we didn’t have before — to speed up our troubleshooting process so we can remedy issues faster if there’s a failure or something going in on the field,” the automation specialist said. “All of which will help us reduce downtime.”
Solution
Motor Control Centers designed to protect workers
The mill selected Allen-Bradley® CENTERLINE® 2100 Motor Control Centers (MCCs) with ArcShield™ arc-resistant technology. These MCCs are designed to protect workers, reduce arc flash hazards, and mitigate damage by containing arc flashes within the equipment.
Rockwell Automation has a history of delivering solutions with unmatched levels of arc flash protection. The CENTERLINE 2100 MCCs feature an expanded range of ArcShield technology for high-current applications, such as those typically used in the mining industry. ArcShield MCCs offer 2.5 times the prior current bus maximum rating for up to 600-volt power applications, up to 3000 amps, and meet the industry’s strict safety standards.
Extensive pre-planning and execution
“A lot of work went into the front end to make implementation as successful as possible,” the automation specialist explained. “The pre-planning and execution were flawless with Walden, Rockwell Automation and BESTECH (engineering services provider) all working together. Rockwell Automation understood our requirements and the CENTERLINE MCCs integrate seamlessly with our DCS system, which made implementation a lot easier.”
“We had a lot of preparations,” added Walden’s Tulloch. “Even though Rockwell Automation was building these new MCCs for the first time, they were able to meet our shipment date so we could pre-test and pre-commission.
“Rockwell Automation and their gear are always easy to deal with,” Tulloch continued. “We’ve installed numerous Allen-Bradley MCCs in the past and with our history together, this installation was like putting on a pair of comfortable shoes.”
Result
Dramatic decrease in CAL rating
Implementation was completed safely and on time in mid-2023.
“We’ve had no issues. We hit our targets, we hit our deadlines, and we hit our commissioning dates,” the automation specialist said. “We just had an audit and it passed with flying colors. Most importantly, these MCCs are safer than any we’ve had to date.”
The mill saw a dramatic decrease in the CAL rating required to work with the new MCCs. CAL ratings indicate the amount of personal protection equipment (PPE) employees must wear when they interact with electrical equipment.
“In the past, the CAL rating to work with this type of equipment was over 40. Now, it’s 5 or less,” the automation specialist explained. “Our employees can work on these MCCs without the level of PPE that used to be required. Without so much PPE, it’s easier for them to come into the switch room and work with the equipment.”
Space saving design & simplified procedures
Adding to that ease is the CENTERLINE 2100 MCC’s new space saving design, which reduces lineup size and overall footprint. The automation specialist also noted that the mill has been able to simplify the safety procedures, forms and signatures needed to perform equipment maintenance.
“We’ve eliminated the long tedious processes that used to be required,” he said. “Preparation to do any kind of maintenance is 100% less because these MCCs have been updated and designed with the electricians in mind who work on the equipment.”
Remote access enhances safety & performance
Because the MCCs also feature Rockwell Automation IntelliCENTER® technology and its built-in EtherNet/IP network, the mill can monitor and diagnose MCC and related component issues remotely. This enhances safety by minimizing the need for employees to approach the equipment and provides access to critical operating data to help reduce downtime.
“Before we went into troubleshooting with barely any information. Now, for example, we have insight into what’s happening in each starter,” the automation specialist explained. “We can pull the data to determine what’s causing issues, whether it’s high amperage, a phase loss or something else, and have the analytics that give us insight before we get out into the field.”
ArcShield is the standard going forward
The mining company expects to replace another 50 lineups of existing MCCs in its mill, tailing and water operations in this region over the next 10 to 15 years and has specified the Allen-Bradley CENTERLINE 2100 product.
“ArcShield is our engineering standard here at the mill going forward. We look forward to more replacements in the future and partnering with Rockwell Automation,” the automation specialist said. “They’ve exceeded our expectations. We never have to worry about product quality or reliability. We can focus on our other priorities.”
Published September 23, 2024
