Air Classifiers, North Star Stage 1 project, control systems, electrical


Fortescue Metals Group


Pilbara, Western Australia


Intellect Systems were engaged to provide an all encompassing End-to-End Industrial Technology Solution for Fortescue Metals Group’s North Star Stage 1 Project comprising of Communications Panels, Distribution Boards, Marshalling Panels, Junction Boxes supply, as well as Control Systems software development, testing and commissioning services.

In addition to the above, Intellect Systems were also engaged to provide post commissioning and ongoing site support to optimise and prove the process while up-skilling and training operations teams.

Business Objective

The North Star Stage 1 Project is a small scale pilot plant designed to utilise and prove new technology to deliver 66% magnetite hematite ore at low operating costs.  Fortescue’s objective and brief to Intellect was to prove the process in a cost effective manner, whilst challenging best practices and innovating where possible.

Challenges To Overcome

The project challenges revolved around the delivery of a relatively unproven process technology, using Fortescue’s generic PPS software standards in a short execution timeframe.  Due to the proof of concept nature of the project much of the design aspects were refined and evolved during the execution process, this required Intellect Systems to think on our feet and react quickly and efficiently to transient project requirements and changes to scope.


The compressed timeframes required Intellect Systems to devise strategies to streamline project execution, this was done by optimising product selection, collaborating with the vendor GE Automation to customise PPS standards, developing customised auto code generation tools and promoting collaboration between teams by tracking task management and software bugs using cloud based software packages.

Project Outcome

Intellect Systems scope of work was completed successfully ahead of schedule and under budget.  The project as a whole was successful in achieving their output and grade targets utilising the newly implemented process and technologies.