Blacks Fork Processing Plant - Reliable Controls Corporation

Project Overview

A large-scale mining facility required a robust and standardized control system for its water supply and distribution network. Previous assessments had identified critical issues in system communications, I/O handling, and interlock programming. Reliable Controls was engaged to engineer and integrate a solution that would enhance system performance and reliability.

SECTOR

Natural Gas

USE CASE

Reliable Controls optimized mining water distribution by standardizing controls, improving I/O handling, and refining interlocks.

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

Control System Engineering

Developed interlock matrices, I/O listings, and control narratives for each well pump.

Lack of Standardization

Developed programming standards, system templates, and interlock matrices to ensure uniformity and efficiency.

Communication & I/O Handling Issues

Implemented structured configurations for seamless integration and improved operational reliability.

Communication & I/O Handling Issues

Implemented structured configurations for seamless integration and improved operational reliability.

Solution Implementation

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

Protective Relay Testing

Tested 280 protective relays using specialized equipment.

Programming Standards

Created standardized templates for equipment controls, I/O handling, and communications.

Visualization & Alarming

Developed HMI process graphics to enhance real-time monitoring.

Safety & Compliance Support

Provided subject matter experts for the HAZOP process.

Results & Benefits

Enhanced Reliability

Standardized system configurations reduced inconsistencies and improved operational stability.

Improved Monitoring

Advanced HMI graphics provided better visualization of water distribution processes.

Successful System Validation

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

Conclusion

By implementing industry best practices, Reliable Controls delivered a scalable, efficient, and standardized control system for the mining facility. The improvements in system integration, communication protocols, and monitoring capabilities have provided the client with a more reliable and maintainable water distribution infrastructure.