Staged Delivery 

The project was staged alongside the mechanical contractor so the upgrade could be carried out without disrupting mine operations. This sequencing allowed the controls scope to be delivered in line with the broader AC upgrade while maintaining plant availability throughout the works. 

Decommissioning and Make-Safe 

The first stage involved disconnecting and removing redundant control wiring associated with mechanical equipment that had been taken out of service. These works made the existing installation safe and cleared the way for the new controls scope. 

New Controls Wiring 

New controls wiring was installed from the existing DB to support the updated plant arrangement. This included a high-volume set of I/O runs, with terminations completed to suit the revised control requirements within the switchroom. 

Instrumentation Integration 

Sensors and associated hardware were installed as part of the upgraded controls package. The works covered placement, termination, and interface readiness so the instrumentation could be brought into the system correctly. 

Testing and Commissioning 

MECS completed testing and commissioning across the upgraded controls scope. This included continuity verification, terminations, point-to-point checks, and commissioning activities to confirm the new installation was ready for service. 

Project Challenges and Solutions 

Working Within an Active Mine 

The main challenge was delivering the controls upgrade inside an operational mining environment. Staging the works with the mechanical contractor allowed the installation to progress in a controlled way and supported zero lost time for the mine. 

Managing Existing Infrastructure 

The HV switchroom contained existing controls infrastructure that had to be worked through carefully. Decommissioning redundant wiring first helped separate old services from the new installation and reduced risk during the upgrade. 

Coordinating the Controls Scope 

The controls package needed to align with the mechanical upgrade and the updated plant requirements. Close coordination across installation, instrumentation, and commissioning ensured the new scope was integrated in the right order and ready for operation at handover. 

Client Feedback 

The completed works delivered the controls scope required to support the AC upgrade, with the staged approach helping the project move smoothly through installation and commissioning. The final result left the switchroom with redundant wiring removed, new controls connections in place, and an upgraded system better set up for ongoing operation.