Project Overview

SAGE were engaged to design, construct, Factory Acceptance Test (FAT) and commission a complete containerised control system for the wet and feeder plants at the Roper Bar Mine site. This mobile control system consisted of two standalone control systems installed in two converted 40ft electrical switch rooms.

The 40ft switch rooms were designed, converted and fitted out and FAT tested in under 7 weeks.  Each switch room consisted of:

• Custom converted 40ft high cube shipping containers including; internal linings, insulation,
• aluminium checker plate floors, custom doors with emergency egress bars, reverse cycle air conditioning,
• internal and external lighting, emergency lighting, fire detection and cable management systems
• Custom built 1000 Amp form 3B switchboards
• Siemens S7 Safety PLC control system including 10” HMI’s
• Profinet enabled VSD’s up to 132kW in size with integrated safety
• PLC and HMI coding and FAT testing in the Adelaide office prior to delivery to the mine site
• Manufactured remote isolator/control stations for all motors.

Capabilities Demonstrated

SAGE successfully provided a turnkey solution to AIR within the tight project time frame of 7 weeks.

This included full Factory Acceptance Testing (FAT) being performed at the Adelaide office and delivery of two 40ft switch rooms to Mataranka in the Northern Territory.

• Project management including estimation, cost planning, procurement, safety assessment , risk mitigation, safety management, stakeholder management, environmental assessment and subcontractor management
• Mechanical design of switch rooms, low/ medium voltage and PLC system design and CADdrafting of electrical control system
• Mechanical and electrical fit out of switch rooms, MCC manufacture, PLC control andremote control panel manufacture/wiring, PLC networking, HMI and system Integration
• PLC, Safety and HMI coding, Including development of functional descriptions
• Factory Acceptance Testing
• Commissioning at Roper Bar site
• Provision of final, as built, documentation
• Ongoing SAGE 24/7 Service support

Technology Utilised

• Integrated safety PLC, including integrated VSD drives safety to CAT 3
• Siemens S7 PLC
• Profinet networking
• Siemens G120 VSD’s with integrated safety on Profinet

Project Highlights

• SAGE exceeded the clients expectations with the delivery of two high quality switch rooms
• The processing plant being modular meant that it was easy to relocate if required.

Project Challenges

• The commissioning stages of the project proved to be challenging due to the remote location ofthe mine site
• The tight project time frame that required the delivery of the switch rooms to the mine sitewithin 7 weeks from the initial purchase order.

Project Outcomes

• The successful delivery of this high quality project