Objective
Modernize the process control network at Conuma Coal’s Willow Creek Mine by replacing an outdated and unreliable ControlNet system with a robust, high-speed fiber optic network using Ethernet/IP.
Solution:
- Process Control Network Upgrade – Designed and implemented a high-speed, fiber-optic Ethernet/IP network to replace the failing ControlNet system.
- PLC & Remote I/O Migration – Replaced communications cards and upgraded remote racks, ensuring seamless communication and improved system responsiveness.
- Fiber Optic Termination & Testing – Installed, terminated, and tested all fiber optic cables to ensure maximum network reliability and performance.
- Downtime Reduction – Eliminated ControlNet’s recurring failures, significantly improving system stability and reducing unplanned downtime.
- Network Segmentation – Isolated the process control network from IT infrastructure, enhancing security, reliability, and performance.
- Seamless Cutover – Executed the migration with minimal disruption to mine operations, ensuring a smooth transition.
Our Role:
- Network Architecture & Migration – Designed and implemented a robust Ethernet/IP control network over fiber optics.
- PLC & Control System Upgrades – Replaced aging PLCs and remote I/O racks for enhanced reliability and performance.
- Fiber Optic Installation & Testing – Terminated and tested all fiber cables to guarantee network integrity and long-term reliability.
- Operational Efficiency & Support – Provided ongoing system optimization, reducing downtime and improving plant-wide communication.