Universal Process / Temperature Controllers
Invensys Upgrades Automation System at Teck Cominco Metals Ltd. Trail Operations with Latest I/A Series Technology
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Phased digital automation project at major Canadian lead and zinc smelting and refining complex migrates to Foxboro controls
FOXBORO, MASSACHUSETTS, USA - Teck Cominco Metals Ltd. selected Invensys Process Systems to implement a new mesh network-based Foxboro I/A Series (www.foxboro.com) automation system for the electrolytic and melting plant processes at Teck Cominco's metallurgical operations at Trail, in southeast British Columbia, Canada.
The Trail complex is one of the world's largest fully-integrated zinc and lead smelting and refining complexes. Total production capacity is approximately 290,000 tonnes per year (TPY) of zinc and 120,000 TPY of lead. The complex manufactures a wide variety of zinc and lead alloys to meet customer specifications worldwide, and also produces twenty additional metal and chemical products.
Invensys implemented the latest I/A Series Version 8.X hardware and software, including a mesh control network, the FCP270 family of field-mounted control processors in fault tolerant configurations, and Foxboro migration integrator modules. Using Foxboro's latest field device system integrator (FDSI) modules, the new control system will also interface with existing Modicon PLC systems. Approximately 1200 I/O points in the electrolytic and melting processes will be controlled and monitored by the new system.
Utilizing Foxboro's proven migration capabilities, the implementation replaces legacy control equipment. The approach utilizes "tune-up" modules that migrate the control, human machine interface and data acquisition functionalities to the I/A Series system, while retaining the existing field wiring, I/O terminations and system cabinets. This innovative and efficient method typically saves from 40 to 50 percent off the cost of a complete system replacement.
I/A Series DCS migration modules are exact physical replacements for the existing input/output (I/O) modules and plug right into the existing system enclosures with no I/O mapping issues. This migration approach, with careful upfront planning, reduces associated process downtime from weeks or even months, to a day or less. This can dramatically minimize lost production.
The new control network will employ the award-winning Foxboro mesh network process control system backbone, which utilizes advanced commercial communications technologies in robust industrial configurations. Providing high-availability, self-healing network performance, the mesh architecture can connect thousands of stations at data speeds up to one gigabit between network switches.
Using capabilities from the wide family of Foxboro controls migration hardware and software products, the new implementation allows Teck Cominco to leverage their investment in existing field equipment, while efficiently upgrading to current digital control technology. In addition, the system is designed to accommodate future expansion as needed.
To support the new implementation, Invensys Systems Canada provided a range of services, including engineering services, system staging and factory acceptance testing, training services, and field services for the I/A Series system at Teck Cominco.
The Invensys Process Systems electrolytic and melting process control migration contract follows two earlier successful Foxboro control system upgrade projects at the Trail complex. Using the same migration concepts, controls in the zinc roasters, the acid plants and the sulphur recovery plant were migrated to Foxboro from Honeywell, while retaining existing field equipment. In the pressure leach plant, Foxboro controls replaced an existing ABB installation. Future phases including a Fisher Provox control system migration program are planned for the cadmium plant and sulphide leaching plant. When these are completed, the entire zinc operation will be under I/A Series control.
About Teck Cominco Metals, Ltd.
Teck Cominco is a diversified mining company, headquartered in Vancouver, British Columbia, Canada. Shares are listed on the Toronto Stock Exchange under the symbols TCK.A and TCK.B and the New York Stock Exchange under the symbol TCK. The company is a world leader in the production of zinc and metallurgical coal and is also a significant producer of copper, gold and specialty metals. Teck Cominco actively explores for mineral deposits throughout the world with exploration offices located in nine countries. Teck Cominco is committed to product and process research in order to enhance the value of the company by developing its intellectual capital. Further information can be found at www.teckcominco.com.
About Invensys Process Systems
Invensys Process Systems (http://ips.invensys.com), a business unit of Invensys plc, provides products, services and solutions that enable today's industrial plants to monitor, manage, and improve the performance of their production assets. In addition to its rapidly expanding Global Solutions group, Invensys Process Systems includes industry-leading brands such as Foxboro, Triconex, SimSci-Esscor, Wonderware, and Avantis, whose products are installed in more than 100,000 plants across the world. These range from small hybrid and batch plants to the world's largest upstream projects, refineries, gas plants, petrochemicals plants, power plants, and pulp and paper mills.
The Invensys Group (www.invensys.com) is made up of five businesses: Process Systems, APV, Eurotherm, Rail Systems, and Controls. The Group is headquartered in London and is listed on the London Stock Exchange, with approximately 30,000 employees working in 60 countries.
CONTACTS:Bob Palmer 508/549-3525 robert.palmer@ips.invensys.com
Paul Miller, 508/549-6240 paul.miller@ips.invensys.com
