Emerson to Digitally Automate Peru's Largest Copper Mining Company | Automation.com

Emerson to Digitally Automate Peru's Largest Copper Mining Company

February 272006
AUSTIN, TEXAS (Feb 27, 2006) — Emerson Process Management announced today that Southern Peru Copper Corp. (SPCC) has selected PlantWeb® digital plant architecture with FOUNDATION™ fieldbus (FF) technology for digital automation of its Ilo Smelter, Peru facility.

In 2004 SPCC launched a project to modernize its Ilo facility smelting capacity to 1.2 million tons/year, reduce SO2 emissions, reduce copper production costs, and increase H2SO4 production for feedstock in another SPCC facility and to export.

SPCC completed the FEED (Front End Engineering & Design) portion of the project in 2004. During 2005, process and control system upgrades were implemented, with commissioning scheduled to begin in early 2006.

Following an in-depth control system analysis, SPCC determined the PlantWeb architecture and its underlying advanced technologies provided the capabilities necessary to achieve the defined project goals.

“We realized we would need to use FOUNDATION Fieldbus, HART®, DeviceNet, Profibus DP, and OPC® [OLE for Process Control] communication technologies on this project,” commented Luis Canzio, Senior Electrical Engineer of SPCC. "Emerson’s PlantWeb digital architecture makes implementing multiple communication technologies as easy as ‘plug-and-play,’ while maintaining communication technology transparency.”

Additionally, SPCC cited the DeltaV™ digital automation system and its embedded multivariable control capabilities as being well-suited to provide control stability to the copper smelting process.

  • Emerson’s contract with SPCC comprises control system hardware, software, and related services, including a Professional Plus Workstation in a PowerEdge 2650 Server.
  • 12 Operator Workstations, and one Professional Workstation.
  • One Base Station in a PowerEdge Server, for remote desktop connections with wireless Ethernet.
  • One Application Station in a Stratus Fault Tolerant Server for OPC connectivity.
  • Nine DeltaV MD redundant controllers.
  • AMS™ Suite: Intelligent Device Manager for HART connected devices.
  • AMS Inside DeltaV for FF connected devices.
  • OPC for PIMS (Process Information Management Systems)
  • Two OPC Application Stations in PowerEdge 2650 Servers, for connecting the DeltaV digital automation system to an existing Bailey Infi 90® system.

    Services Emerson will provide include:

  • Configuration of DeltaV system and AMS suite applications.
  • Cabinet integration
  • FAT/SAT (Factory/Site Acceptance Testing)
  • Commissioning and startup assistance
  • Installation supervision
  • Training
  • Services for Migration of Bailey Infi 90.

    Emerson's migration group, working in cooperation with the local Emerson office, integrated SPCC’s legacy Bailey control system into Emerson’s PlantWeb digital architecture. Migrations services included converting database points, control strategy, and graphic displays, accompanied by an offline configuration checkout prior to actual connection of the new digital plant architecture.

    "Manufacturers across the world are challenged today to extract the most value out of their existing assets," said Tom Snead, president of the process systems and solutions division of Emerson Process Management. "We are enabling manufacturers to gain more value out of their existing assets by making the transition process from older automation systems easier. Users can transition components of their legacy systems at a pace that suits them to take advantage of new capabilities embedded in Emerson technologies."

    About Emerson's Migration Solutions
    According to Larry O'Brien, ARC research director for process industries, "Lifecycle costs, which include costs to upgrade and migrate automation systems, have become more important than initial purchase prices. We believe that Emerson has developed an effective migration strategy for its own legacy systems. Emerson is also one of the few suppliers that has placed considerable focus on a strategy for migration from competitive systems."

    Within the past two years Emerson has released a wide range of migration solutions (www.EasyDeltaV.com/EasyConnect). These solutions have been specifically designed to upgrade a wide range of legacy systems, including those from ABB, Bailey, Honeywell, GSE Systems, Invensys/Foxboro, Siemens, Yokogawa, General Electric, Allen-Bradley, and Modicon, to the DeltaV digital automation system.

    Migration solutions provide flexibility and deliver efficiency
    Emerson's migration products for field connections, operator interface, and control, combined with its simulation, training, and conversion services, reduce installation costs and minimize downtime during an automation system upgrade.

    Using FlexConnect, Emerson can reduce rewiring costs as much as 50 percent and process downtime by 75 percent. Emerson's migration services include database conversion and graphics conversion, or complete redesign of displays. Simulation tools expedite checkout and reduce the learning curve for operator training.

    Local services provide support for fast track migration projects
    "With our migration solutions and in-house domain expertise for a wide range of legacy systems, Emerson makes the modernization process from outdated automation systems to new digital technology a much easier and faster process," said Laurie Ben, director of the migration group at Emerson. "The quicker we can get our customer up and running on the DeltaV system and PlantWeb architecture, the faster they can start realizing the impact of these technologies on their bottom line."

    About Southern Peru Copper Corporation
    Southern Peru Copper Corporation (SPCC, www.southernperu.com) is the largest copper producer in Perú and the tenth largest in the world. It has two concentration plants. One is located at Cuajone (Moquegua). The other is located at Toquepala (Tacna).

    SPCC also owns a Lixiviation plant located in Toquepala wich produced 105.3 millons pounds of Electrolitic Copper type A.

    The Ilo Smelter produces blister copper, and the Ilo Refinery produces Electrolitic Copper Type A, refined silver, gold, and comercial Selenium.

    About Emerson Process Management
    Emerson Process Management (www.EmersonProcess.com), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, food and beverage, pharmaceutical and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb®, Fisher®, Micro Motion®, Rosemount®, Mobrey®, Daniel®, DeltaV™, Ovation®, and AMS™ Suite.

    About Emerson
    Emerson (NYSE: EMR), based in St. Louis, is a global leader in bringing technology and engineering together to provide innovative solutions to customers through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. Sales in fiscal 2005 were $17.3 billion. For more information, visit www.GoToEmerson.com.
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