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Project Details
Client : MountainPeak Mining Ltd.
Location : Inner Mongolia, China
Construction Date : May 2023
Value : $1,320,000
Mining Site PLC/DCS Modernization Project
Hong Kong Saul Electric Co., Ltd.
Mining Site PLC/DCS Modernization Project
Hong Kong Saul Electric Co., Ltd.
Project Background
The client, MountainPeak Mining Ltd., operates a large open-pit mining site in Inner Mongolia, China. The mining operations relied on outdated PLC and DCS systems, resulting in frequent equipment failures, inefficient process control, and high maintenance costs. The client required a comprehensive upgrade to enhance automation, safety, and production efficiency.
Challenges
- Obsolete PLC/DCS hardware with limited vendor support
- Lack of centralized monitoring and remote diagnostics
- Need to upgrade without interrupting critical mining operations
- Integration with a wide range of field devices and ruggedized equipment
- Harsh environmental conditions (dust, vibration, temperature)
Our Solution
Hong Kong Saul Electric Co., Ltd. delivered a full-scope modernization solution:
- Replaced legacy PLCs with Rockwell Automation ControlLogix controllers and upgraded DCS for site-wide process automation
- Deployed a robust SCADA system for real-time monitoring, alarms, and production analytics
- Phased migration to ensure uninterrupted mining operations
- Developed custom interfaces for seamless integration with heavy-duty field equipment
- Provided comprehensive training and documentation for site personnel
Results & Benefits
- Production efficiency improved by 19%
- Unplanned downtime reduced by 62%
- Enhanced process automation and operational safety
- Real-time data access enabled predictive maintenance and faster troubleshooting
- Improved adaptability to harsh mining environments
Contact Us
For more information about our mining automation and modernization solutions:
Email: zoe0159@163.com
Phone: +86 18030274856
Email: zoe0159@163.com
Phone: +86 18030274856
Outcome
The $4 million project was successfully completed in two separate phases with both phases coming in on schedule and the overall costs coming in under budget. Emergency repairs to the facility were completed on December 11th, 2014 which allowed for the facility to operate through the critical winter months. Permanent electrical repairs along with less critical site deficiencies were completed in April and May of 2016 when a longer facility shut-down could be tolerated.
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