Aker Solutions contracted Reliable Controls to engineer control systems for the sulfur burning plant at the Dos Pobres Copper Mine in Safford, Arizona. The mine requires sulfuric acid to recover copper from raw ore, and with the construction of this new plant, the client was able to supply its own sulfuric acid, which significantly reduced the amount needing trucked in. The plant’s design capacity is 1350 STPD.
Control System Design, including PLC and HMI architecture, communication protocols, fiber optic design, and overall network architecture.
Programming Documents and Standards, including a review of Logic Diagrams, Controls Narratives, Control Philosophy, and the Interlock Matrix to ensure consistency and thoroughness against the engineering documents (e.g. P&ID’s, equipment specifications, process descriptions, etc.).
Process Hazard Analysis or HAZOP documentation was carefully reviewed to make certain the controls aspects of the PHA/HAZOP had been captured in the design documentation and programmed in the current logic of the system.
Factory Acceptance Testing documentation was compared against engineering documentation, controls narrative and cause and effect diagrams to secure consistency through the FAT process and assure the system was per the design documentation and functional,
Operations and Maintenance Manuals were also reviewed to ensure they accurately reflect the operability and required maintenance per the design of the system.
The assessment was successfully completed on time during a two-week site visit by the RCC team. A detailed report covering the five categories was provided to the client, along with a gap analysis identifying all gaps relating to standards, logic, design and programming as related to the control system. An action item list was provided, clearly identifying tasks that needed to be completed to ensure system readiness. Thanks to our team for their great work on this project!