Plantwide Control System Greenfield Accelerated Startup
Sector: Mining
- Musgrave, WA
Background
Located in the Musgrave province of Western Australia, 1300km north east of Perth and 1400 northwest of Adelaide, BHP’s West Musgrave project includes the Nebo and Babel nickel-copper deposits and the Succoth copper deposit.
Pre-feasibility studies presented the project as a low-carbon, low-cost, long-life mine producing high-demand copper and nickel for renewables and electrification industries.
Once commissioned it will be a 13.5 Mt/y operations with average production over its 24-year operating life yielding circa 28,000 t/y of nickel and 35,000 t/y of copper.
Vision Stage
December 2020 – February 2021
As part of the pre-feasibility stage, OZ Minerals identified an opportunity within the West Musgrave Project to take a further step forward in the maturity of the convergence of data and computer actions.
This opportunity gave OZ Minerals the ability to develop principles and operational philosophy, from the ground up, to leverage a fully integrated ‘digital’ mine.
OZ Minerals created a vision of the merging of digital technologies – Information (IT) and Operational (OT / PCS) – on which to build the digital mine and looked for assistance in turning their vision into action.
Mipac has been involved in developing highly integrated OT systems for complex operations all around the world and were engaged by OZ Minerals to help turn their vision into action.
Using the vision, Mipac created a high-level control system architecture design and an OT/control network design criteria, creating a robust design for the project to move forward with as the West Musgrave development progressed.
Vendor Selection Stage
February 2021 – May 2021
Armed with a control system design criteria and network architecture, OZ Minerals
wanted to know what the most optimal control system was to help fulfil their vision.
Mipac has experience in implementing most, if not all, control systems and were engaged by OZ Minerals to evaluate and recommend the control system to be used on the West Musgrave Project.
Using the vision, design criteria and architecture, Mipac engaged and evaluated a comprehensive number of control system vendors, producing a final recommendation.
Early Works Stage
June 2021 – November 2021
Following the control vendor selection, Mipac was engaged to develop the specifications to provide a basis of design for the West Musgrave Processing Plant Process Control System (PCS).
In this early works phase, Mipac developed:
1. Plant control system basis of design
2. PLC/controller specification
3. SCADA/HMI specification
4. Alarm strategy specification
5. System architecture drawings
6. Network specifications
Mipac also provided budget estimates for the West Musgrave Control System as part of the feasibility studies.
Early Detail Stage
December 2021 – December 2022
Following the basis of design and specifications for the West Musgrave PCS, Mipac were engaged to complete early detail design. In this early detail phase, Mipac developed:
1. Control network architecture for the minerals processing plant
2. Rockwell PlantPAx standards – These standards were issued and used by vendors providing a control solution, providing a standardised and integrated PCS for West Musgrave.
3. Fieldbus I/O Design – with EPC contractor
4. PCS panel design
5. Communications panel design
MAC stage
April 2023 – current
Following the early detail design phase, Mipac was engaged to provide Main Automation Contracting (MAC) for the West Musgrave Project (now owned by BHP).
As the MAC, Mipac is responsible for delivering a complete and operating integrated process control system (PCS) for the West Musgrave Project, which will monitor, control, ensure plant and asset safety, manage plant operations and achieve business objectives.
Once completed, the site will have fully integrated operational processes and systems, enabling more efficient and dynamic energy management as well as integrated operations, reducing its green footprint as well as the requirement for personnel to be on site.
This work is expected to take two years and engage up to 16 staff.
Want to learn more about Main Automation Contracting?
Manage your project risk with a Main Automation Contractor (MAC)
Coordinating large and complex projects is a challenging task that requires expertise – and that is where your Main Automation Contractor becomes a vital part
Mipac to provide Main Automation Contracting for BHP’s West Musgrave Project
Mipac will provide main automation contracting for what is set to be one of Australia’s largest, lowest cost and lowest emissions copper nickel projects – BHPs’ West Musgrave Project.
As the Main Automation Contractor (MAC), Mipac will be responsible for delivering a complete and operating integrated process control system (PCS) for the West Musgrave Project, which will monitor, control, ensure plant and asset safety, manage plant operations and achieve business objectives.
5 things to look for when appointing a Main Automation Contractor (MAC)
Given that most operations don’t always have in-house expertise, you may need to outsource to a Main Automation Contractor (MAC). Outsourcing this responsibility will allow you to tap into trusted experts who specialise in the field who can guide you through the whole process and offer ongoing support.
