JPMC Abyad Mine Rehabilitation and Upgrade of Control and Electrical System from Classic Control to PLC/SCADA System

Project Overview

The Jordan Phosphate Al-Abyad Mine used to operate on a legacy classical control system that lacked modern automation and data acquisition capabilities. The purpose of this project was to completely upgrade the mine's obsolete control infrastructure into a modern, centralized PLC and SCADA-based system, while simultaneously executing a complete rehabilitation of the MCC panels and supplying of field instrumentation.

The project scope covered the following:
1. MCC panels complete upgradation.
2. Supply and Commissioning of SINAMICS G120 VFD Drives and Commissioning of ABB ACS800 Drives.
3. PLC Control and SCADA operation system (Siemens ET200SP CPU and IOs and WinCC Professional V19).
4. Supply and Installation of Field instruments (Electromagnetic flowmeters and densitymeters).
5. Supply and Installation of Motorized valves for the underflow pumps and the top agitator.
6. Programming and Commissioning of Bulk Scan system for accurate reading of both plant's feeding and production (ton/hr).
7. Replacement of Local control boxes.
8. Fixation and replacement of damaged cable ladders for electrical installations.
9. Supply of Industrial power plugs.
10. Lighting system.
11. Supply and termination of missing Power, Control and Instrumentation cables.
12. Supply and Installation of CCTV cameras and paging system.
13. Control room rehabilitation.

The Beneficiation section of the plant was upgraded to Siemens ET 200SP CPU 1514 controller. Dedicated Siemens S7-1200 PLCs were deployed for the three thickener rakes. The plant was integrated into a central Siemens TIA Portal V19 environment utilizing WinCC Professional SCADA software.