Automating the driverless railcars vital to mining sector

Challenge

As an Original Equipment Manufacturer (OEM) for an industry driven by process performance, Metso Minerals is a company who expects results from it’s suppliers.

Metso Mineral’s fully automated Rotary Railcar Dumper Systems set the worldwide industry standard, with a technologically advanced list of standard features for system dependability, efficient operation and long service life.

Their railcar dumper systems are currently used by Australia’s leading resource giants including Fortescue Metals Group, BHP and Rio Tinto.

Outcome

Delivering Outstanding Performace

As many railcar off-load facilities are unmanned, system reliability and optimisation are crucial. To ensure targets are met, SAGE undertakes a multi-tier testing process:

Simulation

The PLC and SCADA packages configured for each unique system, undergo a detailed simulation testing process prior to being integrated with the railcar dumper.

Factory Acceptance Testing

Once integrated with the railcar dumper, a Factory Acceptance Test is undertaken in line with the customer’s specific standards. Factory Acceptance Testing includes field devices, electrical circuits, electrical control panels as well as the control system.

Site Acceptance Testing

On site, the systems are installed and commissioned, before Site Acceptance Testing is undertaken. Full testing documentaiton is produced and provided to the client.

Optimisation

To ensure that maximum efficiences and output are achived, the railcar dumper system is subject to an optimisation process.

Railcar dumpers are meeting target capacities of up to 90 cars per hour and 9,072 of material mtph.

Technology

• Citect SCADA

• Rockwell Logics 5000

• Siemens Drives

• GE Proficy

• GE Cimplicity

• Schneider Unity Pro

• Hima Safety

Capabilities demonstrated

• All SAGE personal were fully trained and inducted to meet Metso and client JSEAs

• Software programming and integration

• CAD drafting and electrical design

• Factory Acceptance Testing

• Remote installation and commissioning

• Site Acceptance Testing

• Ongoing service support including electrical inspections and maintenance