Efficiency by Design
As the programme was focused on the typically complex time-intensive task of mining tailings, ensuring that the process was set up to succeed from the outset was of upmost importance for Kazakhaltyn.
Silumin-Vostok LLP, a Recognised System Integrator in the Rockwell Automation PartnerNetwork™ programme was selected to deliver the solution, due to its vast experience with similar integration projects. Prior to this, the control system was planned to be designed on equipment from other vendors, but when specificiations were near completion, Rockwell Automation’s offering was chosen as the most appropriate solution due to its vast experience in the sector.
Silumin-Vostok deployed Rockwell Automation’s Integrated Architecture under a single EtherNet/ IP network so all devices on the network could be configured centrally through ControlLogix 5570 controllers. This not only meant that Kazakhaltyn had visibility of the entire control system environment, but if any unit or part of the architecture needed to be replaced, it could be configured and set up automatically once connected to the network, saving time and resource.
Rockwell’s Software Studio 5000® automation system was also used to design, configure, program and maintain the controllers and Silumin-Vostok integrated an Application Code Manager (ACM) tool to streamline workflows, reuse library objects and enable auto content generation. The controllers were also fitted with POINT I/O™ modules.
Further to this, all devices were organised within four device-level rings (DLR) - each for a particular production area, and there was also a dedicated redundant controller for the elution process at the Aksu plant.
DeviceLogix™ Smart Component Technology and E300 Electronic Overload Relays were included as part of the integration to reduce the risk of motor failure by protecting the motors and providing diagnostics information, as well as define any built-in adaptive logic. PowerFlex 753 and 755 AC Drives were installed to ease programming and configuration, as well as reduce set-up time, training and operation.
For workers, the connected infrastructure provided the support needed to day-to-day.
Kazakhaltyn plants were equipped with new effective process automation systems which could enable further scaling and integration at an enterprise level.
Thus, the plant is ready for further improvements on the journey to the Connected Enterprise.