Location
Pilbara, Western Australia
Industry
Mining
Disciplines
Engineering, Manufacturing
Overview
This project supports the planned replacement of three ageing reclaimers at an iron ore stockyard facility in the Pilbara, Western Australia. The reclaimers play an important role in the stockpiling and outloading of iron ore and are nearing the end of their operational life.
As part of this project, the new reclaimers require control systems and functional safety design, configuration and integrated testing.
Scope
Intellect Systems was engaged to design and supply a stockyard simulation PLC test panel and provide subject matter expertise for the safety software library, design of the new reclaimers and delivery of the Anti-Collision System (ACS).
Our scope included:
- Design, manufacture and install a PLC simulation test panel
- Integrate simulation hardware for ACS testing
- Develop PLC and safety software, including function block libraries
- Provide control systems and functional safety engineering support
- Design, program, and commission multiple construction protection zones to facilitate safe construction areas while the stockyard continued operations
- Coordinate and conduct Factory Acceptance Testing (FAT) for panels and switchrooms
- Interface and support third-party simulation vendors
- Deliver system documentation, change management, and validation reporting
Smarter Solutions
A key challenge for the client was converting the existing Anti-Collision System into a Safety Integrity Level (SIL) rated system, while also accommodating the dimensions of the new reclaimers, which had the potential to increase machine-to-machine interactions during regular operations. As the reclaimers are critical assets within an operating brownfields environment, these changes needed to be developed with minimal disruption to ongoing operations. Intellect Systems was engaged to provide specialised engineering support to the EPCM across functional safety, control systems, standards and multi-vendor systems integration.
Our team developed a comprehensive suite of functional safety documentation to support the project’s safety lifecycle, including critical reviews of vendor documentation to ensure compliance. This included successfully integrating ageing brownfields infrastructure, client standards, Australian standards and multiple vendor designs.
Intellect Systems developed key components of the control software, including a bespoke PLC and safety function block library tailored for safety and scalability, while also providing a standardised template from which all software could be based. The team also coordinated integrated testing across multiple vendors, ensuring that all control components operated as a unified system.
Intellect Systems was also tasked with developing and assembling a portable simulation panel based on Schneider Electric’s M580 and M580S safety PLCs, aligned with the client’s approved hardware standards. The panel was designed to replicate real-world control system conditions, enabling engineers to safely test programmable logic, anti-collision sequences and machine movement controls as a functioning digital twin. Importantly, this simulation platform supported the definition of requirements, preliminary ACS design and scope development for the SIL-rated system and was used to assist in the selection of the successful vendor during the tendering process.
To address the high-risk interface between ongoing port operations and construction activities, Intellect Systems designed, programmed and commissioned construction protection zones using multiple layers of safety, ranging from software interlocks to hardwired safety trips, to prevent stackers and reclaimers from entering active construction zones.
Throughout the project, the engineering team maintained a strong focus on client communication, delivering detailed documentation including a functional safety management plan, safety requirement specifications, functional specifications, test plans and design drawings. The team’s knowledge and expertise proved instrumental in identifying and resolving issues early, significantly reducing commissioning time and on-site risk.
