RTIO EII MCC Replacement Project

Project Profile

Decommissioning, replacement installation and commissioning of Seven (7) outdoor MCCs for Trippers -TR7EN, TR8EN, TR9EN, TR10EN, TR11EN, TR12EN and TR32EN, for thyssenkrupp Industrial Solutions as part of the Rio Tinto East Intercourse Island (EII) Stacker Replacement Project. Works included functional safety upgrades, rectification and installation upgrades.

Products Handled

Iron Ore


45 mtph


  • ABB ACS880-11-07A6-5 VVVF drives
  • EATON 1P 63A Surge Filter
  • PNOZ S4 Safety Relay
  • PNOZ S7 Safety Relay
  • OMRON 6A 6P 24VDC
  • Non-Latching Relay
  • CISCO 8-Port Network Switch and Network Router
  • SCHNEIDER 12-Slot PLC Rack with Power Supply and M580 CPU
  • PLC and SCADA

Our Involvement

  • Engineering, design and drafting, manufacture, and delivery of seven (7) single sided outdoor MCC units
  • Certified to AS AS/NZS 3439 or AS/NZS 61439
  • Certified IP66 external MCC enclosures
  • Certified to Arc flash rating 40kA
  • Certified to AS1170.1&1 Wind region D
  • Installation and testing of equipment, including but not limited to:
    • PLC hardware, network switches, safety relays and voltage regulation/power conditioning of power supply units and variable speed drives
    • Modicon M580 PLCs and Extended I/O
    • ABB ACS880VVVF drives
    • TeSys T LTMR Motor Protection Relays and Custom Logic
    • Schneider NSX100N MCBs
    • Cisco Network switches and Modbus over TCP/IP Communications
    • PILZ PNOZ S4 and S7 Safety Relays
  • Electrical MCC Factory Acceptance Testing with PLC & SCADA availability for I/O and functional testing
  • Creation of detailed construction and commissioning work pack documentation
  • Decommissioning of existing MCCs and associated infrastructure prior to the new equipment installation
  • Removal and Replacement
    • Lifting and Rigging
    • Working at Heights (Scaffolding, EWP)
  • Electrical construction including, but not limited to:
    • Cable containment and cable support systems
    • Supply and installation of engineered cable requirements
    • Terminations and commissioning
  • Recommissioning of all motors, hydraulics and field instruments during the project delivery
  • QAQC of installation with supply of associated As-built drawings

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