Mine design project services

From feasibility studies and planning to mine design / development and project management - integrated solutions from mine to port and from plant to enterprise bring substantial capital savings through early involvement

Want to make better mine planning and design decisions?

The pace of technology development increases. The demand for digitalization, enhanced plant efficiency and improved energy consumption drive the need for optimized engineering of mining and mineral processing facilities. Miners, mill and plant operators thus are turning to companies that provide automation, electrical and digital solutions meeting the technical, security and execution requirements of these complex facilities.

Our offering

Enterprise value

Flawless execution

Common approach

Benefits

Adding value to your project

Embarking on a major mining project is a high stakes and high risk investment. Years are spent in exploration, geotechnical studies, various levels of feasibility studies and sourcing funding to establish a productive mining operation generating sufficient financial returns to attract investors to the project.

Investors often sink huge sums of money into projects expecting that they will achieve the desired returns over time. While there are many risks that are exogenous to the project – exchange rates, commodity prices etc. – there are many project centric hazards that can be controlled. Doing so effectively will lead to improved financial performance.

As a supplier of key systems, products and services , we can add significant value to a project if engaged early in the project lifecycle. Considerable savings in both CAPEX and OPEX can be achieved. It is this key supplier involvement that we define as ‘enterprise value’.

EPCM companies in mining: redefining relationships

Main automation and electrical contractor for large industrial projects

This approach moves the product developers from their traditional role of equipment supplier to that of an independent contractor performing the role of an engineering, procurement and construction contractor. ABB defines this role as that of a main automation and electrical contractor. In making the transition from vendor to contractor, the MAC/MEC is required to adopt a more proactive approach during the execution of a project. This involves a very close cooperation with the client organization and other contractors and suppliers to develop best-in-class solutions, to implement those across the facilities and to manage the interfaces with other participants ensuring effective integration of all components and systems.

ABB's comprehensive product and systems offering to cover the entire spectrum of an integrated scope of supply

The MAC/MEC role is distinguished from the traditional vendor role in three significant ways:

The scope of supply involves services and supply of products with the emphasis on the ability to provide the services element. The scope of work requires contribution of the MAC/MEC throughout the full project lifecycle, from front-end engineering and design (FEED) to completion and start-up.
The work requires significant coordination and information exchange between multiple project participants.
The MAC/MEC is responsible for coordination of the overall systems and manages the interfaces to facilitate integration.

There are also significant differences from a project execution perspective where these types of projects involve multiple participants including process designers, construction contractors, utility providers, regulatory authorities and government agencies:

First, the scope of work is broader than a conventional supplier scope and is focused on the overall solution and not the individual products that provide the solution.
Second, the MAC/MEC works closely with the customer and overall plant designer in the FEED phase to develop the system concept and basic operational specifications.
Third, once the project moves into the full execution phase, the MAC/MEC has the responsibility to provide coordination and interface between the major EPC contractors to ensure the concepts and requirements developed are implemented effectively and the standardization of design is achieved across the facilities.
Fourth, the MAC/MEC provides the system solution utilizing its own products in combination with third party supplied products. It integrates these with the process and utility equipment provided by the EPC contractor and assists with the installation of the completed systems under the direction of the EPC contractor.
Finally, the MAC/MEC has the responsibility to work under the direction of the EPC contractor at the construction sites to achieve final commissioning and start-up of the facility.

As a global leader in the design and supply of process automation and power systems for a broad range of industries, ABB has easily made this transition from a main product supplier to an overall solutions provider. Leveraging our expertise around the globe, ABB has developed the “Book of MAC/MEC”, a robust project execution methodology which, combined with extensive product and industry knowledge, provides customers with a level of service not available from the traditional EPC contractors.

Added value throughout all project phases

Project execution
Our execution methodology is based on modern project management techniques supported by well trained and qualified professional resources, proven systems and tools. The focus of our approach is to ensure the project scope is well defined at the outset, the work is planned well in advance, responsibilities are agreed between all participants and detailed project specific plans covering are established, implemented and followed.

ABB has developed the Project Execution Map to support the project management process in a most effective way. The map outlines the structure and scope of a typical automation or electrification project from the Front End Engineering and Design phase through to acceptance. It provides information on the primary execution processes and the various project plans needed to achieve flawless execution throughout all project phases.

In order to achieve a common approach for project execution, the map shows the relationships between the customer’s internal execution processes, the MAC/MEC and the EPC contractors and how these processes interact. The map describes the four main project phases:
Front End Engineering and Design

Detailed design, engineering and manufacture
Construction and installation
Completions and closeout
Front end engineering and design

MACMECvalue
A main automation and electrical contractor provides value to the owner/operator in all project phases

Importance of early involvement in the project
Early involvement in the development stage of a project has a tremendous impact on overall effectiveness of the final selected solutions. The long term benefits results in total cost of ownership savings. Despite acknowledging that key suppliers can present significant value to projects when engaged early, many investors feel that they are at risk of being exploited through non-competitive procurement practices. This does not need to be the case. Early engagement does not necessarily require the abandonment of competitive bidding practices. It simply suggest that the basis for competition should focus on a supplier’s ability to deliver enhanced value to the project rather than simply the lowest price.

The MAC/MEC participation already in the FEED phase of a project lays the foundation for the development of best in class solutions for the project. The FEED phase has two basic elements: a technical aspect and a work process aspect.

Working in cooperation with the plant owner and process designer, ABB utilizes its unique combination of technical expertise and detailed execution capabilities to provide the technical concept definition, project standards, common functional design criteria and generic equipment specifications. Each organization (owner, designer and ABB) has its own internal execution standards and requirements.

These internal processes reflect the basic principles of the respective organization and are the basis for how each approaches the various execution phases. A balance between the project specific requirements and the basic work processes must be achieved. Integration of the respective work processes must also be guaranteed to enable the transfer of critical engineering data and documentation. This integration of work processes and establishing a common approach to execution are key elements in achieving flawless project execution.

Resulting in total cost of ownership savings

The ABB execution capability, coupled with ABB's broad products portfolio, technical expertise and global manufacturing facilities, offers customers a range of project services that provide predictable and consistent results and help customers deliver their business objectives.

The ABB approach of having one Main Electrical and Automation Contractor involved at early stages considers that the electrification, control and instrumentation systems of a mine are expected to be in an horizontal integration through the different process areas. It means that only one electrical distribution system is designed for the plant and the same applies for the overall control and instrumentation systems.

Consistent integration
The horizontal integration allows consistency in the design facilitating the same communication standards and protocals among all protection and communication devices, considering the same basis for the dimensioning of equipment and ensuring a robust and optimized system.

Integrated design and engineering
It also allows the system to be designed as a whole, considering all the necessary interfaces and optimizations possible to define an efficient and customized design according to process needs.

Optimized project management
The ABB approach is frequently led by the same core team of ABB specialists which is coordinated by certified and experienced project managers and technical leader, as well as engineering team covering all necessary disciplines and a site services team which commission and supervise the erection of the systems.

Adaptation to various project drivers
Each project has different project priorities, some of them are driven by delivery or execution time, some of them look for the best possible design for very rough environmental and site conditions. The ABB system approach allows to adapt to all these variables

Optimized CAPEX and OPEX
By looking not only at the equipment cost, but to the overall installation costs tremendous savings can be achieved. For instance the use of containerized solutions can ensure faster delivery time or optimized concrete e-house layouts. Furthermore this approach embraces aspects such as fastest possible execution time, logistic chain optimization, energy efficiency solutions, lowest maintenance and lowest OPEX cost solutions are also foreseen.

Overall risk reduction
An integrated system approach also reduces risks of delays, cost overrun, change management by having one overall project management and execution team. At the same time one set of commercial terms and conditions is ensured.

References

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We also offer

Consulting and engineering

Advanced digital services

Upgrades

Maintenance

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Periodic maintenance report for GMD

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Minerals plant fingerprint

Overall Equipment Effectiveness (OEE), reliability and maintenance assessment, life cycle strategy, training needs, spare parts criticality analysis, process control performance, cyber security, financial impact, business case development

Hoist Performance Fingerprint

A structured audit of your entire hoist system covering the electrical and mechanical parts helps identify hidden failures or shortfalls in regulartory compliance, preventive maintenance and training

Mining process performance fingerprint

Our experts assess, measure and analyze your processes: crushing, grinding, flotation, thickening, dewatering, leaching and stockpile management, and provide an estimate of potential improvement.

Conveyor Fingerprint Services

Maintenance and field assessments of the customer's conveyor systems compared to industry best practices, to help improve maintenance strategies, avoid production losses and minimize unplanned maintenance interventions

Control system, safety and cyber security consultancy

Diagnosis and audits to identify opportunities and solutions to improve DCS configuration, equipment performance, production processes, safety regulatory compliance and cyber security

Drive system consultancy

An expert analysis for your drive system to identify its improvement potential. You select the most promising potential improvements among the identified ones for further exploration.

Go to Consulting and engineering Overview

ABB Ability™ Remote assistance for grinding

Call our system experts via ABB SupportLine to get rapid support. ABB engineers will guide you to solve the problem, or will troubleshoot directly using the remote secure connection.

ABB Ability™ Predictive Maintenance for mining

Proactive asset management integrates and analyses condition data from all types of equipment used in mining to reduce maintenance costs and increase operational efficiency

ABB Ability™ Predictive Maintenance for grinding

Easy access to GMD system parameters and visualization, taking a look into the past, considering real-time data in the present and assessing the future, remote expert recommendations to normalize operation and prevent possible downtime

ABB Ability™ Condition Monitoring for belts

Digital service tailor made for predictive maintenance of conveyor belts that collects and tracks data from the conveyor belt to provide real time information about the failure potential, thus enabling planned and timely action.

ABB Ability™ Performance Optimization for mining

Assess improvement potential based on current plant operation, stabilize and optimize performance with advanced process control, automate maintenance and performance reporting

ABB Ability™ Smart Hoisting

Hoist performance fingerprint (audit), customized, prioritized reporting, identify issues before they become problems, Insights to optimize operations

ABB Ability™ Performance Optimization for material handling

Increase availability, efficiency and productivity of the entire bulk material haulage and processing chain using data

ABB Ability™ Performance Optimization for control systems

Issues causing control system performance deterioration are often difficult to diagnose because of their random nature. If left unaddressed, these issues may lead lo system failure and unscheduled downtime.

ABB Ability™ Performance Optimization for control loops

Automation in PID loops typically has a half-life of six months, meaning that half of all loops undergo some degradation in performance within their first year of deployment.

ABB Ability™ Cyber Security Services

A connected world increases the probability of cyber attacks. Smart, defense-in-depth solutions allow to Identify, Protect, Detect, Respond and Recover from cyber threats.

Go to Advanced digital services Overview

Hardware upgrades

Hydraulic station valve block upgrade kit for mine hoists, brake card upgrade kit for mine hoists, AC/DC drive upgrades for shovels and draglines, DCS Parts StepUp - more powerful and up-to-date hardware, Drive upgrades and retrofits

Software upgrades

Control systems modernization and control room consolidation. Connect a mix of different DCS / SCADA / PLC systems - both from ABB and other major vendors - into one integrated HMI

Go to Upgrades Overview

ABB Field Service Management

Brings together the right people, with the right platform and processes to provide customized maintenance plans

ABB Ability™ Remote assistance for grinding

Call our system experts via ABB SupportLine to get rapid support. Our engineers will try to guide you to solve the problem, or will troubleshoot directly using the remote secure connection

ABB Ability™ Predictive Maintenance for mining

Proactive asset management integrates and analyses condition data from all types of equipment used in mining to reduce maintenance costs and increase operational efficiency

ABB Ability™ Predictive Maintenance for grinding

Electric truck services

For Kiruna electric mining haulage trucks EMT35 and EMT50

ABB Ability™ Condition Monitoring for belts

Go to Maintenance Overview

Spares and consumables

Training

Service Agreements

ABB Ability™ Collaborative Operations

Parts services for control systems

ABB Parts Fingerprint, new parts, emergency delivery, refurbished parts, parts repair, exchange and test services, preventive maintenance kits, inventory access program, parts stepUp, root cause analysis

Spare parts for grinding drive systems

Audits and a list of spare parts with fixed prices, delivery times for an agreed period, with a fast and efficient ordering process

Spare parts for mine hoist systems

A single source of supply for the complete system, service and spare parts with the lowest possible life cycle cost

Go to Spares and consumables Overview

Long-term service agreement for mining assets

All maintenance and service offerings combined to keep your mining assets (GMDs, hoist systems, electrical equipment etc.) running

ABB Mining Care

The global standardized service agreement framework that helps cut complexity, control cost and maximize capital

Go to Service Agreements Overview

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