Full Design of Controls, Infrastructure Solution to Optimize for Growth at Trap Rock and Granite Quarry

See how Tri Tech helped this trap rock and granite quarry with their control challenges.

Full Design of Controls, Infrastructure Solution to Optimize for Growth at Trap Rock and Granite Quarry

The Situation

The beginning of this story sounds at first a little like a middle school math problem: a greenfield quarry site aimed to deliver over 4,000,000.00 tons of varying aggregates annually to the market. This production area is just over a mile wide, and is located on over 1,500 acres total. They were looking for a partner who could be responsible for the design and delivery of all controls, power control, network infrastructure, IT infrastructure, reporting, visualization, safety, and instrumentation.

The Customer’s Need

For a project of this scale – spanning IT infrastructure to instrumentation – the customer needed a structured approach to decision-making. Three key considerations shaped their evaluation:

  • Risk: Ensuring the project could be completed successfully within the required timeframe.
  • Support: Establishing reliable access to assistance when needed.
  • Scalability: Implementing a system capable of growing with future operational demands.

By prioritizing these factors, the customer would then be able to move beyond specific equipment brands or capital expenditure concerns and focus on the fundamental goal: creating a plant that is efficient to operate, easy to maintain, and adaptable for future growth.

The Tri Tech Solution

Tri Tech was the main automation contractor selected to work with this quarry. We walked the customer down the path of a PlantPAx solution from Rockwell Automation to solve all of these challenges. Rockwell Automation offers a fully characterized control system which means we can simulate the system before engineering even starts, and verify that it is going to perform. This is done through the PlantPAx estimator, which is used to size the system based on variables specific to each unique situation. Along with other standard and off-the-shelf features, this helped drive down the risk during our execution phase. The supportability of this system also happens to be second to none. The success of the PlantPAx system is well-documented, and is open for all to leverage. Rockwell and their partners also carry a large inventory base; this all adds up to a site that is optimized for operational success. Lastly, the site/code is architected in a very modular and repeatable fashion. When it’s time to grow, it is basically just copy and paste. Achieving a standardized solution and making the most of great design and delivery practices has this quarry set up for immediate success and long-term growth.

The scope can be broken down to the following areas: Network Architecture, Power Controls, Controls, HMI, IT Infrastructure and Commissioning.

Network Architecture/Design:

Design of a robust network leveraging redundant REP rings and managed switches made for a robust network for Ethernet control. Redundant fiber-based rings each rated at Gig speed at all distribution points formed the backbone of this distributed, Ethernet-controlled site. By utilizing Stratix switches, we were also able to integrate the network as a part of the overall control strategy of a smart system proactive in detecting problems. By taking advantage of the Stratix Faceplates and Premier Integration, we can get detailed information directly on the HMI for monitoring, reviewing, and troubleshooting. Managed switches also allowed for Quality of Service (QoS) to be leveraged for safety over Ethernet deployment.

  • 28 Managed Switches Redundant REP Ring, Safety Over Ethernet, QoS.
  • Stratix Faceplates and Premier Integration

Power Control:

The project had 176 motor loads for a total load of approximately 12,000HP rated at 480VAC and 4160VAC. Large Power Control Packages, Drive Systems, MCC’s, and Custom Soft Starters were all a part of our deliverables. Custom Engineered MCC’s from Tri Tech Automation allowed for the customer to leverage their corporate wiring standard convention while utilizing the latest features of Rockwell’s Power Control. Smart Overloads and VFD’s allow for advance control and diagnostics.

  • PLC
  • HMI
  • Proactive Features
  • 28 Managed Switches Redundant REP Ring, Safety Over Ethernet, QoS.
  • 176 Motors
  • 12,000 HP, LV, MV, ranging from 2HP to 800HP, Load Sharing
  • Distributed Safety
  • 2,000.00 Tons per Hour
  • Almost 1 Mile Side to Side
  • Electrical Design: 750 drawings
  • Controls Design
  • Programming
  • Network Design: Physical Media, Network, VLAN’s, Etc.
  • Server Infrastructure
  • Thin Clients
  • Historian/Reporting