el brocal mining application paper - hanforddrama · sociedad minera el brocal s.a.a. mining...

El Brocal Mining Application Paper

ELECTRONIC SYSTEMS TECHNOLOGY 509-735-9092 (O)

415 N. QUAY STREET • KENNEWICK, WA 99336 of 3 www.esteem.com

Wireless Mining Project

Wins Ecological Award

As with all heavy production industries, mining needs a reliable source of uncontaminated water. Reclamation and treatment of this resource is critical to the daily operation of a mine. Automation of water recycling systems have not always been a top priority, but as Sociedad Minera El Brocal S.A.A. mining operations in Peru has shown, through their award winning water control network, automation of non-production systems can greatly increase both efficiency and system reliability.

Sociedad Minera Brocal S.A.A. mining company of Peru operates in the extraction, concentration and commercialization of polymetallic ores, mainly zinc, lead, copper and silver throughout multiple districts in Peru. At the Colquijirca Huariaca Concentrator Plant, located in the Tinyahuarco District of the Province of Pasco, the water recycling system was manually controlled by an operator. The operator would read the level displays in the reservoir and turn on or off the pumps remotely with a handheld device. Without immediate system feedback, there was always a general uncertainty whenever a change was made to the 7km long recycling system. An overflow could result in contamination and would deprive the water needed for plant operation. There is also the unnecessary energy consumption to operate the pump when the water reservoir is full. To automate the water recycling system, Sociedad Minera installed a Supervisory Control and Data Acquisition (SCADA) network of Rockwell Automation controllers. Rockwell controllers are the standard at Sociedad Minera due to their robust operation and standard Ethernet interface. The SCADA network monitors the water levels in the reservoir and makes predictive decisions when to turn on or off the distant pumps. The Rockwell controllers need to communicate though an Ethernet based network. Because of the 7 km distance, 14,000 elevation above sea level and topography of the area, fiber optic cable would have been too costly and difficult to install (Figure 1). The systems integrator for this project, Industrial Controls S.A.C., researched wireless Ethernet technology to be the most cost effective and selected ESTeem Wireless Modems as the hardware manufacturer. ESTeem is a member of Rockwell Automation’s Encompass partner program. Both Industrial Controls (the local ESTeem distributer) and the ESTeem product line have a great reputation in the mining industry for reliability.

Eric Marske Product Manager ESTeem Wireless Modems Sam Amaral South American Sales Manager ESTeem Wireless Modems

Figure 1: System Layout




The requirements on the wireless system were that the communication be Ethernet based, license free and have the ability to repeat with a highly reliable product. The ESTeem 195Eg, 2.4 GHz, wireless Ethernet modem met all these requirements and was selected for the application. The 195Eg operates in the unlicensed 2.4 GHz band and any wireless Ethernet modem can be a repeater for any other in the network. The 195Eg can be mounted outdoors with its NEMA4 mounting kit, making installation very simple and cost effective (Figure 2). Each phase of the radio integration was an excellent example of how to design a reliable wireless network. Phase 1 – Design and Hardware Testing Industrial Controls SAC and the customer conducted a design review of the proposed wireless network prior to conducting any on-site testing. They reviewed the specifications for each wireless Ethernet network, contacted the vendors and conducted evaluation testing for each product. Once the wireless hardware was selected they proceeded to the testing phase. Phase 2 – On-Site Radio Survey Once Phase 1 design was completed, all locations in the network were physically tested with the hardware that will be installed at the site. Site survey testing included measuring receive signal strength, RF background noise and data transmission efficiency. The purpose of this testing is to confirm the initial wireless design and also make any site adjustments if an on-site problem is identified. Phase 3 – Installation/Commissioning After the radio design plan was evaluated and accepted, Industrial Controls SAC completed the installation of the wireless hardware and performed a site commissioning using the same testing techniques uses during the radio site survey. The testing was conducted on the installed hardware and the results should be equal or greater than the values tested during the site survey. The purpose for all this extensive testing is that the wireless network is providing the “backbone” for all communications in the water recycle system. If any wireless link is unreliable then all devices connected to that link will also be unreliable. A properly designed, installed and tested wireless network can be as reliable as any cabled communication system.

Figure 2: ESTeem 195Eg Outdoor Mounting




The Sociedad Minera network received an award from the minister of labor in Peru for their improvements in the environment (Figure 3). The wireless system has operated flawlessly for over two years and since been expanded by two more sites. The wireless Ethernet SCADA network of Rockwell and ESTeem Wireless Modems is an excellent example of how automation can provide automation and reliability to a difficult water network.

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(EST) dba ESTeem Wireless Modems® with all rights reserved.

Under the copyright laws, this document may not be copied, in whole

or part, without the written consent of EST. Under the law, copying

includes translating into another language. EST, EST logo, and

ESTeem are registered trademarks of Electronic Systems Technology,

Inc. Simultaneously published in the United States and Canada. All

rights reserved. For more information contact: Electronic Systems

Technology, Inc., 415 North Quay Street, Kennewick, WA 99336

Ph: (509) 735-9092 Fax: (509) 783-5475

Figure 3: Award Ceremony

el brocal mining application paper - hanforddrama · sociedad minera el brocal s.a.a. mining...

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