Enhancing Retort Process Efficiency and Compliance at a Nevada Gold Mine

Project Overview

Reliable Controls enhanced the Retort process at a Nevada gold mine, ensuring compliance, improving safety, and optimizing efficiency through advanced automation and system integration.

SECTOR

Mineral Processing

USE CASE

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LOCATION

Client Objective

Fluor Corporation engaged Reliable Controls Corporation to perform relay testing, electrical pre-operational testing, and commissioning services at the Pueblo Viejo mine, a multi-billion-dollar mining facility in the Dominican Republic. With a design capacity of 24,000 tons per day, this world-class mine required precise electrical testing and commissioning to ensure safe and efficient operations.

Challenges and Solutions

Large-Scale Electrical System Complexity

Conducted rigorous testing of 280 protective relays across multiple voltage levels.

Ensuring System Integrity Before Operation

Performed pre-operational testing, including defect identification and loop checks, to validate system readiness.

Lack of Standardization

Implemented paperless documentation for relay testing, including “as-found” and “as-left” results with defect identification and supporting images.

Solution Implementation

Reliable Controls executed a comprehensive engineering and system integration process, including:

Protective Relay Testing

Tested 280 protective relays using specialized equipment.

Custom Work Packages

Developed tailored testing procedures to ensure accuracy and efficiency.

Paperless Documentation

Recorded testing results digitally, including before-and-after conditions and defect tracking.

Electrical Pre-Operational Testing & Commissioning

nspected instrumentation and electrical equipment. Identified defects and maintained a punch list for issue resolution. Conducted DCS & PLC integrity checks. Performed calibration, loop checks, and I/O function verification. Updated drawings with redlines for final documentation.

Results & Benefits

Reliable Controls executed a comprehensive engineering and system integration process, including:

Enhanced Electrical System Reliability

Comprehensive relay testing ensured protection across multiple voltage levels (220kV, 34.5kV, and 4.16kV).

Optimized Operational Readiness

Pre-operational testing and commissioning validated system performance before startup.

Successful System Validation

The SAT was completed, documented, and transmitted to the client, ensuring compliance and operational readiness.

Seamless Integration with Client Operations

RCC became the go-to team in the field, reinforcing trust and collaboration.

Conclusion

Reliable Controls Corporation played a critical role in ensuring the electrical reliability and operational readiness of the Pueblo Viejo mine. Through rigorous testing, precise commissioning, and innovative documentation methods, RCC delivered a seamless and efficient service, solidifying its position as a trusted partner in the field.