Process automation specialist Endress+Hauser South Africa has designed and built a portable calibration hub to bring its world-class process calibration technology to Mutanda Mine SARL (Mumi mine), an open-pit copper mine located in a remote area of the Democratic Republic of Congo.
Ghislain Mbayo, process control superintendent at Mumi, says that the project began when the mine urgently required a state-of-the art calibration and maintenance facility to ensure quality and production uptime and reduce unplanned shutdowns and cost. However, it did not want to build a facility due to the time it took to obtain building rights.
“Because we are situated so remotely, there had been no daily assistance with proper calibration at our process plant, something that we knew posed a threat to our production target,” adds Mbayo.
Thinking out of the box resulted in a solution in a box, and the mine commissioned the Endress+Hauser South African office to design, build and supply its calibration and maintenance needs in one 3 x 6 m container. The completed unit, which has since been transported by road from Johannesburg to its destination in the DRC’s Katanga Province, had to fulfil the mine’s objectives to obtain accurate measurements via advanced calibration and verification technology, conduct training on specific instruments and calibration methods, and enable both testing and fault finding.
(Left) Wouter Carstens, Head of Department, Service at Endress+Hauser and Ghislain Mbayo, Process Control Superintendent at Mumi.
Wouter Carstens, head of the service department at Endress+Hauser South Africa, led the project. “Our primary aim was to meet the needs of the customer and ensure that what we designed would optimise the mine and work in an efficient and safe manner when placed in a remote site, a must for any mining operation,” he explains.
The internal and external layout of the container was key to fulfilling the requirements. “This means that everything from the grids to the desks, plug points, windows and door were fitted,” highlights Carstens. “The container we chose is also resistant to corrosion. This, together with its low maintenance and high quality, makes it an ideal product in the often harsh African territory and climate.
“Once the container reaches its destination, it’s practically plug and play,” he adds. “This particular container requires 220 VAC power, but we are firmly committed to the unique needs of our diverse clients and can supply solar power, or any other customisation that they need.”
Support and after-sales service will continue, with Carstens and a technician assisting with setup of the container and providing training on all the equipment. Annual checks will also take place to ensure that everything is properly maintained.
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