Tài liệu Case Study - Century Zinc pdf

CENTURYZINC North West Queensland, Australia Scope: A case study on the use of the KRONE TERMINATOR™ system for wiring control equipment for the Pasminco Century Mine and port loading facility. Date: September 1999 Prepared by: Jeff Glen, Manager Power & Control Division KRONE (Australia) Technique Pty Limited With responsibility for installing controls for the mine site processes, Stork Electricalcompleted approximately 93,000 terminations using the KRONE system. According to Paul Hopkins, Project Manager, the system is much easier to use compared to screw terminals and more than twice as fast, resulting in substantial time and labour savings for the project. Mannesmann Rexrothsupplied hydraulic power packs for actuation of the Severe Service Ball Valves. Sam Soury, Manager, Electronics and Controls, agreed that the main benefit of the IDC technology was termination speed as it eliminates the need for stripping and screwing. Coogee Chemical, operating the mine's chemical reagent plant, believes reliability is the main advantage of the IDC technique over screw type terminals. According to Erik Nielsen, Electrical Superviser, the company has never had a loose connection since it began using the KRONE TERMINATOR™ system in 1996. The Pasminco Century Mine is in one of the most remote areas of Queensland, approximately 250 km northwest of Mt Isa. Century will be one of the world's largest zinc mines, yielding approximately 880,000 tonnes of zinc concentrate and 70,000 tonnes of lead concentrate, or around 8% of global production. Project managed by the Century Minenco Bechtel (CMB) Joint Venture, the AU$850 million development include an underground pipeline and the development of port loading facilities at Karumba. In September 1998 site electrical works began for the Century project, requiring a high degree of control cabling for low voltage applications. The criteria for selecting a connecting sys- tem were reliability in harsh conditions, low installation cost, reduced installation time and less risk of faulty installation. With the capacity to produce corrosion and vibration resistant Insulation Displacement Connections (IDC), KRONE's TERMINATOR™ solution was written into the electrical design specifications for the mine site's control equipment by Tim Smith, Lead Electrical Engineer for the CMB Joint Venture. Uniformity of terminals is important for large operations like the Century project as there is often a need to not only maintain but add to installations once they are in place. The TERMINATOR™ system is ideal for mine environments as it is designed for applications that require a large number of connections and for machinery where screw connections might loosen. It also reduces routine maintenance and delays in commissioning. Aerial view of the processing plant and the open cut pit at the Pasminco Century Project, Lawn Hill, NW Queensland Switchboard marshalling cabinet Time Savings: In the factory 1. Per termination 45 seconds 2. Per 100,000 terminations 1250 hours 3. @ $35.00 per hour $A43,750 On site 1. Per termination 45 seconds 2. Per 100,000 terminations 1250 hours 3. @ $50.00 per hour $A62,500 The total approximate time saving on this project were 2,500 hours and $106,250. Universal Motor Kontrol (UMK)supplied 15 Motor Control Centres, consisting of more than 200 tiers of its new Kontrol 5000 to the Century Mine site, believed to be the largest 690V installation in Australia. The MCC’s featured 4000A ACB incomers and busties, over 450 drives and PLC cubicles which required in excess of 5000 terminations using TERMINATOR™. UMK's Production Manager estimated that the use of KRONE's TERMINATOR™ solution resulted in time savings of around 45 seconds per terminal. With a short lead time on the project, the high speed terminal system was crucial in enabling UMK to deliver on schedule. Barclay Mowlem Constructioninstalled wiring at the port loading facility in Karumba for PLCs, the digital control system, field units and instruments. Mark Richardson, Electrical Superviser, said that the TERMINATOR™ solution, including KRONE's wire cutting and termination tool, was highly effective due to the time savings achieved and ease of use by the electrical installation team. J&P Richardsonprovided water filtration equipment to the Century port site at Karumba. With around 2,000 terminals to install, Clayton Berlin, Electrical Design Engineer, found the KRONE modules easier to use and more reliable than other connection systems. Foxboro Australia, designed and constructed the project's complete field control and automation system. With responsibility for running the mine's equipment, Foxboro was a large user of KRONE TERMINATOR TM modules for the main PLC panels. Switchboard manufacturer R G Laddbuilt 30 marshalling cabinets containing 2000 blocks for Foxboro, with each block holding 10 terminals. Brenton Stokes, Project Manager, commented that TERMINATOR™ was easy to install and that the terminations were carried out on site without problem. Central Coast Switchboardswas sub-contracted by Weir Engineeringto supply the control panels for the dewatering process, and utilised the TERMINATOR™ range of products. Underground Pipeline (304km) Aerial view of the Port loading facilities at Karumba, Queensland For further information please contact: KRONE (AUSTRALIA) TECHNIQUE PTY LTD PO Box 335 Wyong NSW 2259 2 Hereford Street Berkeley Vale NSW 2261 Tel: (02) 4388 4422 Fax: (02)4388 4499 Email: kronehlp@krone.com.au Web Site: www.krone.com.au Specifications Cabling Details: Approximately 100,000 terminations were completed in the factory and 100,000 terminations completed on site using KRONE's IDC technique. Cabling Contractors:Stork Electrical (mine site) and Barclay Mowlem (port site) Motor Control Panels:Universal Motor Kontrol (UMK) Control Equipment: Foxboro Australia Cable Details: Steel wire armoured Delkron cable sizes 0.5mm to 1.5mm. KRONE Products Used 6461 5 201-00 1.5mm 2 Terminator™ Through Module, 10-line white (1-0) 6461 5 202-00 1.5mm 2 Terminator™ Disconnect Module, 10-line white (1-0) 6461 2 021-00 Earth Terminal, screw to screw version 6461 2 022-00 Earth Terminal, screw to IDC version 6461 2 013-00 Profil to DIN Adaptor 6461 2 035-00 Fuse Holder, 6mm pitch 6461 2 004-00 Test Plug with Socket, single pole 6461 2 007-03 Plug Numbers, printed 10-20 6468 3 029-01 Plug Numbers, printed 10-100 6468 3 029-02 Plug Numbers, printed 1-0 6468 3 029-03 Plug Numbers, printed 1-50 6461 2 034-00 Hinged Label Holder 6461 2 011-02 Standard Bridging Bar, 2-line 6461 2 011-10 Standard Bridging Bar, 10-line 6461 2 069-00 50V Bridging Bar, 10-line 6461 2 005-00 Terminator™ Termination Tool 6461 2 032-00 Terminator™ Wire Cutting & Termination Tool 6089 1 121-02 0.4-0.8 Series 2 Disconnection Module Nos 1-0 6468 5 050-10 0.4-0.8/0.65-0.9 Instrumentation Interface Disconnection Module 6468 2 048-10 0.4-0.8 Series 2 Earth Module Front page (from top left): Pasminco Century processing plant, Motor Isolation Control box, Distributed Control System (DCS) cabinet, Port loading facilities at Karumba, . 5 20 1-0 0 1.5mm 2 Terminator™ Through Module, 10-line white ( 1-0 ) 6461 5 20 2-0 0 1.5mm 2 Terminator™ Disconnect Module, 10-line white ( 1-0 ) 6461 2 02 1-0 0. pole 6461 2 00 7-0 3 Plug Numbers, printed 1 0-2 0 6468 3 02 9-0 1 Plug Numbers, printed 1 0-1 00 6468 3 02 9-0 2 Plug Numbers, printed 1-0 6468 3 02 9-0 3 Plug Numbers,