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ENG450 – Engineering Internship Brad Smith – 30331929 1 of 70 22/04/2009 Final Year Engineering Internship Report Murdoch Engineering Faculty of Minerals and Energy ENG450 – Engineering Internship Prepared By: Brad Smith Academic Supervisor : Associate Professor Graeme Cole
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Page 1: Final Year Engineering Internship Report - Murdoch …researchrepository.murdoch.edu.au/760/1/Report.pdf · ENG450 – Engineering Internship Brad Smith – 30331929 1 of 70 22/04/2009

ENG450 – Engineering Internship

Brad Smith – 30331929 1 of 70

22/04/2009

Final Year Engineering

Internship Report

Murdoch Engineering

Faculty of Minerals and Energy

ENG450 – Engineering Internship

Prepared By: Brad Smith

Academic Supervisor : Associate Professor Graeme Cole

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Table of Contents

1.0 DISCLAIMER................................................................................................................................................. 7

2.0 INTRODUCTION ........................................................................................................................................... 8

2.1 OBJECTIVES................................................................................................................................................... 8

2.2 REPORT FOCUS .............................................................................................................................................. 8

2.3 COMPANY INFORMATION .............................................................................................................................. 8

3.0 LIST OF ABBREVIATIONS......................................................................................................................... 9

4.0 PROJECT OUTLINE..................................................................................................................................... 9

4.1 FUNCTIONAL SEQUENCE – HEMATITE ......................................................................................................... 10

4.1.1 Train Unloading and Stockpiling........................................................................................................... 10

4.1.2 Reclaiming and Ship Loading................................................................................................................ 11

4.2 FUNCTIONAL SEQUENCE – MAGNETITE....................................................................................................... 11

4.2.1 Train Unloading and Stockpiling........................................................................................................... 11

4.2.2 Reclaiming and Ship Loading................................................................................................................ 11

4.3 STORAGE FACILITY DESIGN PARAMETERS .................................................................................................. 12

5.0 CONVEYOR DESIGN ................................................................................................................................. 14

5.1 FUNCTION.................................................................................................................................................... 14

5.2 SAFETY........................................................................................................................................................ 14

5.3 CONVEYOR DESIGN..................................................................................................................................... 14

5.4 TRIPPER DESIGN .......................................................................................................................................... 15

6.0 SAFE CONVEYOR DESIGN ...................................................................................................................... 16

6.1 CONVEYOR STOPPING ................................................................................................................................. 16

6.1.1 Belt Drift Switch..................................................................................................................................... 17

6.1.2 Belt Rip Detector ................................................................................................................................... 17

6.1.3 Blocked Chute Switch ............................................................................................................................ 17

6.1.4 Speed Sensing Element .......................................................................................................................... 17

6.2 EMERGENCY STOPS ..................................................................................................................................... 18

6.2.1 Pull Wire Switch .................................................................................................................................... 18

6.2.2 E/Stop..................................................................................................................................................... 19

6.2.3 Emergency Push Button (EPB).............................................................................................................. 19

6.3 START-STOP CONTROLS .............................................................................................................................. 19

6.3.1 Local Control Panel............................................................................................................................... 19

6.3.2 Start Up Warning................................................................................................................................... 20

6.4 ISOLATING................................................................................................................................................... 20

6.5 TRIPPER CONTROLS..................................................................................................................................... 21

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6.5.1 Local Control Panel............................................................................................................................... 21

6.5.2 Remote Control Panel............................................................................................................................ 21

6.5.3 Tripper Position Sensor ......................................................................................................................... 22

6.5.4 Tripper Travel Limit .............................................................................................................................. 22

6.5.5 Ultrasonic Level Sensor......................................................................................................................... 23

6.5.6 Catenary Snag Sensor............................................................................................................................ 24

6.6 DUST SUPPRESSION ..................................................................................................................................... 24

6.6.1 Dry Dust Controller............................................................................................................................... 24

6.6.2 Wet Dust Controller............................................................................................................................... 25

7.0 ELECTRICAL DESIGN .............................................................................................................................. 26

7.1 HIGH VOLTAGE ........................................................................................................................................... 26

7.2 SINGLE LINE DIAGRAMS ............................................................................................................................. 27

7.2.1 Updating the Single Line Diagram ........................................................................................................ 27

7.2.2 Cable Sizing ........................................................................................................................................... 29

7.3 SWITCHROOM .............................................................................................................................................. 30

7.3.1 Schematic............................................................................................................................................... 31

7.4 INSTRUMENTATION AND CONTROL PACK.................................................................................................... 34

7.4.1 Instrumentation and Controls Layout .................................................................................................... 35

7.4.2 Connection diagram .............................................................................................................................. 36

7.4.3 Schematic............................................................................................................................................... 41

8.0 LIGHTING DESIGN .................................................................................................................................... 42

8.1 CONVEYOR GALLERIES ............................................................................................................................... 43

8.2 TRANSFER TOWERS ..................................................................................................................................... 47

8.3 MCC AND TRANSFORMER COMPOUND ........................................................................................................ 49

8.4 STORAGE SHED ........................................................................................................................................... 51

8.5 STAIRS AND HANDRAIL ............................................................................................................................... 51

8.6 EMERGENCY LIGHTING................................................................................................................................ 51

8.7 DESIGN RESULTS......................................................................................................................................... 51

8.8 LIGHTING AND SMALL POWER DRAWINGS .................................................................................................. 52

9.0 PLC DESIGN................................................................................................................................................. 56

9.1 ETHERNET ................................................................................................................................................... 56

9.2 DEVICENET.................................................................................................................................................. 57

9.3 MODBUS...................................................................................................................................................... 58

9.4 CONTROLNET.............................................................................................................................................. 58

9.5 INTERNSHIP CONTRIBUTION ........................................................................................................................ 59

10.0 REFERENCES .............................................................................................................................................. 60

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11.0 BIBLIOGRAPHY ......................................................................................................................................... 61

12.0 APPENDIX A – KIOP ELECTRICAL DRAWINGS................................................................................ 62

13.0 APPENDIX B – GPA DRAWINGS ............................................................................................................. 63

14.0 APPENDIX C – SAFE-T-DRIFT DATA SHEET ...................................................................................... 64

15.0 APPENDIX D – SAFE-T-RIP DATA SHEET............................................................................................ 65

16.0 APPENDIX E – NHP PULL WIRE SWITCH DATA SHEET................................................................. 66

17.0 APPENDIX F – IFM DATA SHEET........................................................................................................... 67

18.0 APPENDIX G – START UP WARNING DATA SHEET ......................................................................... 68

19.0 APPENDIX H – CABLE CALCULATION EXAMPLES......................................................................... 69

20.0 APPENDIX F – 3D MODEL SCREENSHOTS.......................................................................................... 70

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Table of Figures and Tables

FIGURE 1: STARTUP WARNING SIREN.............................................................................................................. 21

FIGURE 2: REMOTE CONTROL PANEL RECEIVER ....................................................................................... 23

FIGURE 3: ULTRASONIC LEVEL SENSOR......................................................................................................... 26

TABLE 1: SINGLE LINE DRAWING LIST............................................................................................................ 30

TABLE 2: VSD SCHEMATICS DRAWING LIST.................................................................................................. 38

TABLE 3: DOL SCHEMATIC DRAWING LIST ................................................................................................... 40

TABLE 4: EXAMPLE OF INSTRUMENTATION AND CONTROLS PACK DRAWINGS............................. 41

TABLE 5: INSTRUMENTATION AND CONTROLS DRAWING LIST ............................................................ 42

TABLE 6: CONNECTION DIAGRAM DRAWINGS............................................................................................. 50

TABLE 7: LIGHTING LEVELS FROM AS1680.................................................................................................... 54

FIGURE 4: STANDARD CONVEYOR LIGHTING DESIGN PLAN................................................................... 56

FIGURE 5: STANDARD CONVEYOR LIGHTING DESIGN ISOMETRIC ...................................................... 56

FIGURE 6: STANDARD CONVEYOR LIGHTING DESIGN RENDERED MODEL ....................................... 57

FIGURE 7: CONVEYOR CV520 LIGHTING DESIGN PLAN ............................................................................. 58

FIGURE 8: CONVEYOR CV520 LIGHTING DESIGN ISOMETRIC................................................................. 58

FIGURE 9: CONVEYOR CV520 LIGHTING DESIGN RENDERED MODEL.................................................. 59

FIGURE 10: TRANSFER TOWER LIGHTING DESIGN PLAN ......................................................................... 60

FIGURE 11: TRANSFER TOWER LIGHTING DESIGN ISOMETRIC............................................................. 60

FIGURE 12: TRANSFER TOWER LIGHTING DESIGN RENDERED MODEL.............................................. 61

FIGURE 13: SWITCHROOM LIGHTING DESIGN PLAN.................................................................................. 62

FIGURE 14: SWITCHROOM LIGHTING DESIGN ISOMETRIC ..................................................................... 62

FIGURE 15: SWITCHROOM LIGHTING DESIGN RENDERED MODEL ...................................................... 63

TABLE 8: LIGHTING DESIGN RESULTS............................................................................................................. 64

TABLE 9: POWER DESIGN REQUIREMENTS ................................................................................................... 66

TABLE 10: LIGHTING AND SMALL POWER DRAWING LIST ...................................................................... 67

FIGURE 16: ETHERNET NETWORK .................................................................................................................... 70

FIGURE 17: CONTROLNET NETWORK.............................................................................................................. 72

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1.0 Disclaimer

Confidentiality is required for this document as stipulated in the Internship Contract.

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2.0 Introduction

2.1 Objectives

The purpose of this report is to demonstrate that the intern actively participated and

learnt while conducting the engineering internship.

2.2 Report Focus

The focus of this report is the Karara Iron Ore Project. The report details the electrical

engineering design of the new storage shed and associated facilities. Special attention is

given to safe design to prevent injury to personnel or damage to equipment. The report

will discuss theory of the electrical design and identify what the intern’s contribution was

on the Karara Iron Ore Project.

2.3 Company Information

Maunsell AECOM is an engineering design firm that has expertise in the following fields:

Buildings; Environment, Water & Civil Infrastructure; Minerals & Industry; Power &

Energy and Transport. With a large parent company AECOM, Maunsell has been able to

draw on a global pool of talent to become an industry leader in engineering design.

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3.0 List of Abbreviations

AS Australian Standards

BF Belt Feeder

CV Conveyor

DWT Dual Wagon Tipper

GPA Geraldton Port Authority

KIOP Karara Iron Ore Project

MGI Mount Gibson Iron Ore

4.0 Project Outline

Maunsell AECOM was selected to produce the detailed design for a new minerals

handling and storage facility in Geraldton. The minerals will be stored in 2 sheds to be

located at the Geraldton port on the Geraldton Port Authority’s (GPA) premises. The

minerals will be transported into the GPA from the Mid West region of WA by rail. The

Karara mine site is located approximately 320km North-North-East of Perth and 215km

East-South-East of Geraldton in the shire of Perenjori.

The GPA currently has an existing network of conveyors that move minerals from the

train unloader to the storage sheds, then to the available ship loaders. Most of the

conveyors are owned and operated by the GPA. However, Mount Gibson Iron (MGI) has

a storage facility also located on the GPA premises that has associated conveyors.

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Maunsell will be designing both the Hematite and Magnetite storage sheds, the Dual

Wagon Tipper (DWT), Berth 7 Ship Loader and all associated conveyors. Stage1

includes only the Hematite shed and the associated conveyors. Stage 2 works will

complete the outstanding tasks.

4.1 Functional Sequence – Hematite

4.1.1 Train Unloading and Stockpiling

Hematite minerals may be supplied by two different train unloaders, the GPA train

unloader or the Dual Wagon Tipper (DWT). The GPA train unloader uses bottom

discharge cars to release the minerals onto the conveyor system that will move the

minerals to conveyors CV702 via CV601. The DWT uses flat bottom cars that are tipped

to release the minerals onto feeders that transfer the minerals onto CV701 which

transfers the minerals onto CV702. Please refer to Appendix F – 3D Model Screenshots

while reading the following section.

CV702 is used in both unloading systems and therefore only one unloader may be used

at a time.

CV702 moves the minerals approximately 357m and transfers the minerals using gravity

onto CV703.

CV703 is 94m long and transfers minerals using gravity onto CV704. The transfer point

for CV703 and CV704 is located inside the Hematite shed.

CV704 is a shuttle conveyor that will change position in order to be used to direct the

minerals to either the Hematite or Magnetite sheds. In the “Hematite” position the

minerals from CV703 lands onto CV704 and is carried for 12 m and transferred using

gravity onto CV705.

Tripper conveyor CV705 runs the full length of the storage shed (166m) and will be able

to transfer (using gravity) the minerals at discrete locations along CV705.

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4.1.2 Reclaiming and Ship Loading

The stored minerals will be reclaimed by front-end loaders and tipped onto the feeders.

Two of the three feeders will be operational at one time, and will transfer the minerals

using gravity onto CV520.

The feeders are approximately 12m long and transfer the minerals onto CV520 using

gravity.

CV520 will move the minerals approximately 135m and transfer the minerals onto CV521

using gravity.

CV521 travels approximately 82m to transfer the minerals onto CV522 using gravity.

CV522 will move the minerals 166m to CV523 and transfer the minerals using gravity.

CV523 will move the minerals 45m and transfer the minerals using gravity onto CV503

an existing GPA conveyor that feeds the Berth 5 shiploader.

4.2 Functional Sequence – Magnetite

4.2.1 Train Unloading and Stockpiling

The magnetite minerals will only be available via the DWT. The minerals will follow the

same path as the Hematite unloaded from the DWT until it reaches the end of CV703.

The Hematite then transfers onto CV704 in the “Hematite” position, the Magnetite will

transfer onto tripper conveyor CV706. This is possible because CV704 in the “Magnetite”

position will align the CV704 bypass chute with tripper conveyor CV706.

CV706 will run into the Magnetite shed covering the full length of the shed. The minerals

will be discharged at discrete locations using gravity into stockpiles for storage in the

Magnetite shed.

4.2.2 Reclaiming and Ship Loading

Minerals from the Magnetite shed will be reclaimed using a drag-chain reclaimer that will

transfer the minerals onto CV708.

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The magnetite may be transferred directly to the ship loader without being stored.

CV706 will be able to transfer minerals onto CV707 bypass conveyor that would transfer

the minerals directly to CV708.

CV708 will transfer the minerals onto CV730 using gravity.

As mentioned previously, Hematite may be transferred onto CV730 for ship loading to

Berth 7.

CV730 will transfer minerals onto CV731 using gravity.

CV731 will transfer minerals onto the Berth 7 ship loader boom conveyor.

4.3 Storage Facility Design Parameters

The storage facility houses mined and processed minerals while until they are able to be

loaded onto the transport ships. The storage shed and conveyors have a minimum

specification as shown below:

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Hematite Storage Facility

Material: Hematite Iron Minerals – Lumps & Fine Particles

Storage Capacity: 170,000 tonnes

Facility Inloading Rate: 5,000 tph (design)

Facility Outloading Rate: 5,000 tph (design)

Magnetite Storage Facility

Material: Magnetite Concentrate

Storage Capacity: 170,000 tonnes

Facility Inloading Rate: 5,000 tph (design)

Facility Outloading Rate: 5,000 tph (design)

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5.0 Conveyor Design

5.1 Function

The conveyors are put in place to move the minerals from point A to point B at a

designated rate. The reason for this is to minimise the time taken to move the minerals.

Conveyors are also the lowest operating cost method of moving large quantities of bulk

minerals.

The main function of the tripper conveyor is to convey minerals from the feeding

conveyor so that it may be stockpiled within the storage shed to be later reclaimed for

ship loading. The tripper is a short upward incline portion of the conveyor, elevating and

discharging the minerals while maintaining the continuity of the belt. The tripper needs to

be a mobile wheel driven unit that can travel along the storage shed to allow for even and

selective transferring of the minerals. In order to take advantage of gravity and the

maximum storage capacity of the shed, the conveyor and tripper are located at the apex

of the shed.

5.2 Safety

The conveyor and tripper are required by Australian standards to be designed

manufactured, commissioned, tested and maintained by Australian Standards and other

statutory regulations. AS1755 Conveyors – Safety Requirements, outlines safe practices

for conveyor and conveyor systems design and refers to other appropriate standards.

The mines safety act and the WA mining regulations are statutory regulations that detail

further mandatory requirements.

5.3 Conveyor Design

For the KIOP project there are a few challenges for the design team. The project location

is on a “brown fields” site, meaning that the storage shed is being designed for an

existing site. The brown fields site provides restrictions on where new equipment and

structures can be placed as they need to co-exist within an existing facility and

infrastructure.

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Additionally, the conveyor system needs to be designed to accommodate two different

minerals: Hematite and Magnetite. In order to correctly design power requirements two

sets of calculations are required to determine the worst case scenario. Other

considerations revolve around different material characteristics which may require

different transfer point geometries and chute materials appropriate to both minerals.

5.4 Tripper Design

The purpose of the tripper is to discharge the conveyed material into the storage stock

pile. The tripper is also required to discharge the materials at specific locations to

regulate the stockpile level. A simple yet effective design is employed by Maunsell’s

design engineers. This design also reduces the cost to the customer. Refer to drawing

1681-EL-DRG-1287 in Appendix A – KIOP Electrical Drawings. The tripper needs to be

light and durable to maximise the loads imparted by the tripper onto the shed steel

structure and maintain an economic structural solution.

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6.0 Safe Conveyor Design

The main purpose of the instrumentation when designing a conveyor system is to make

the system safe for people and machinery while it is being used, maintained or repaired.

Instrumentation also provides a greater level of control over the system which can lead to

greater operating efficiency therefore saving money.

When designing such a system there is a risk of over designing. A responsible engineer

should design a functional system within the bounds of the available budget and overall

project philosophy. This approach is generally more difficult to achieve than the

“standard solution” but the end result will be more suitable for the application.

The minimum safety requirements for designing a conveyor will be discussed below and

can also be found in AS1755, WA mines regulation and the mines safety act.

6.1 Conveyor Stopping

When a conveyor is stopped for any reason, it should stop in the shortest time possible

and remain stopped until started again (AS1755, 2000). Conveyor stops may occur as

operational, protective or emergency stops. In each case AS1755 outlines the design

criteria.

Operational stopping is straight forward. The shut down sequence is activated and the

conveyor is brought to a stop by the VSD reducing the current output to the motor. When

the power is disconnected, the conveyor should remain stationary. This is achieved by a

gearbox locking system that is called a “hold back”. Gravity prevents the conveyor from

moving forward (as it is generally designed with an incline) and the hold back prevents

the conveyor from moving backwards.

Protective stops occur in a situation where damage or injury is likely to occur to

equipment or persons in the near vicinity. AS1755 (section 1.6, pg.7) describes a

protective stop as

“A stop control provided for the protection of the conveyor or personnel from a

hazard which, when activated, stops the conveyor and includes emergency stop

controls.”

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On KIOP protective stop controls include:

Belt drift switches (BDS)Belt rip detector (BRD)Blocked chute switch (BCS)Speed sensing element (SSE)Catenary Snag Switch (CSS)

A brief description of each is given below.

6.1.1 Belt Drift Switch

Belt drift switches are located on the side of the conveyor with the primary function to

indicate when the conveyor is drifting off the conveyor idler supports. A signal is sent to

the PLC that will activate a timer and after the timer, a fault condition is initiated and the

conveyor stops the drifting belt before it causes damage or injury. Refer to Appendix C –

Safe-T-Drift Data Sheet.

6.1.2 Belt Rip Detector

Belt rip detectors are used to signal to the PLC when the conveyor belt has been

damaged or ripped. Therefore the BRD’s are generally located a few meters after the

transfer point on a conveyor. This location is chosen because, the place where the belt

is most likely to rip is at the transfer point, and therefore the rip is detected soon after

occurring, and therefore any damage to equipment is minimised. This location is also

where to objects are most likely to stab through the belt. See Appendix D – Safe-T-Rip

Data Sheet

6.1.3 Blocked Chute Switch

The blocked chute switch becomes activated when the transfer chute from one conveyor

to another becomes full and runs the risk of overflowing. This creates an alarm that will

stop the conveyor. The protective stop will prevent spilling that could cause damage to

equipment or injury to personnel.

6.1.4 Speed Sensing Element

The speed sensing element is used to indicate to the PLC that the conveyor is travelling

too slowly. However, the PLC does not look for the under speed immediately at startup.

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A time delay (blanking interval) is allowed for the conveyor to start, once the timer runs

out the flag is set. If the under speed sensor is activated another timer starts and at the

end of this timer a fault condition is initiated and the conveyor is stopped. See Appendix

F – IFM Data Sheet.

6.2 Emergency Stops

The definition of an emergency stop is defined by AS1755 (section 1.6, pg.6) as:

“A manual or automatically operated system designed to stop a conveyor system

in the shortest practicable time in an emergency.”

Devices used to provide sufficient emergency stop capabilities are:

Pull-wire switch (PWS)E/Stop on the Local Control Panel (LCP)Emergency push button (EPB)

6.2.1 Pull Wire Switch

The pull wire switches are located on walkways that run adjacent to the conveyor and

each pull wire section may be spaced up to 100m, (i.e. a double-sided pull wire switch

can operate up to 200m). AS1755 also specifies where the pull wire switch is to be

mounted along the conveyor. For grounded conveyors the pull wire switch should be

mounted between 900mm and 1500mm above ground level. For elevated conveyors the

height limit may be exceeded as long as the pull wire switch is below the sheer point of

the conveyor (AS1755). In the event of an emergency, the pull wire is pulled, thereby

disconnecting the hardwire electrical circuit to the VSD. When the hardwire circuit is

interupted three different actions occur to stop the conveyor.

First the main contactor that feeds power to the VSD is opened completely, thereby

removing power to the VSD. Second, the PLC will receive the fault message from the

pull wire switch via the digital input and then send a message to the VSD to stop

operating. Third an internal hardwire that allows the Insulated Gate Bipolar Transistors

(IGBT) to fire is broken, physically stopping the VSD operations even if the first two

operations fail. For more information refer to Appendix E – NHP Pull Wire Switch Data

Sheet

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6.2.2 E/Stop

Each conveyor has a local control panel that has an E/Stop button that is wired up to the

same hardwire circuit as the pull wire switch. Therefore, if the E/Stop is pressed then the

process to stop the conveyor is the same as the pull wire switch.

6.2.3 Emergency Push Button (EPB)

The emergency push button has only been used in one location, on CV704. The

emergency push button functions in the very same manner as the E/Stop and pull wire

switch. The emergency push button is generally located where there is some dangerous

moving equipment that may require an immediate stop to prevent injury or damage to

equipment.

6.3 Start-Stop Controls

In order for the storage facility to operate safely, sequential control of the conveyors is

required for starting and stopping operations. The starts and stops can be operated via

the PC control panel or operated at the local control panel (LCP) of each conveyor. In

most operational circumstances the PC control panel will be used to start all the

conveyors in the correct sequential order. The local control panel would be used when

testing the conveyor or under special circumstances.

6.3.1 Local Control Panel

All conveyors have a local control panel (LCP) that is located at the head (drive) of the

conveyor. The local control panel is one of the devices used to control the conveyor. A

normal local control panel has two push buttons, one 2-position switch and an E/Stop

push button. The two push buttons are used for start and stop operations. The 2-

position switch is used to select local or auto control and the E/Stop has been discussed

previously. In some circumstance where the conveyor is reversible, a second switch is

available to select forward or reverse.

Conveyors are not the only devices to have local control panels, the direct online devices

also have local control panel. These devices are generally smaller motors such as dust

collectors or water pumps. Normally, the DOL local control panel has one push button,

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one 2-position switch and one E/Stop. The push button is used as the start and the 2-

position switch is used for the local and auto selection option.

6.3.2 Start Up Warning

AS1755 also requires that a prestart warning be given that a conveyor is about to

operate. This requirement is met by installing a start up warning (SUW) unit that is

controlled by the PLC digital output card. The start up warning is a siren accompanied by

a flashing light to effectively warn nearby personnel that the conveyor is about to start.

Refer to Appendix G – Start Up Warning Data Sheet.

Figure 1: Startup Warning Siren

6.4 Isolating

For safety during repairs and maintenance, an isolating device is connected in series

between the source and the load (in most cases a motor). The isolator’s purpose is to

totally remove power to the device. AS1755 clearly states that at least one form of

isolation is to be installed for every conveyor drive and that device should be lockable in

the open (isolated) position. The isolator should not be lockable in the closed position

and is to be manually operated.

The Mines Safety and Inspection Regulations1995 section 5.29 states that all electrical

equipment on the mine site is provided with an isolating device. This means that

isolating devices are included for all other motors such as those for dust collector sand

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water pumps. In most cases 2 such isolators have been provided per device; one at the

motor control centre and the other a field isolator.

The above standards don’t specify the location of the isolating device. In most cases the

device will be isolated at the MCC. However, only authorised personnel have access to

the switchroom. In order to provide a best practice design, Maunsell includes a second

standalone isolator that is located very near to the device. This allows added safety for

the person who is working on the equipment by providing a visual confirmation that the

device is isolated.

6.5 Tripper Controls

As previously discussed, the tripper allows a cost effective manner to discharge the

minerals into the storage shed. To provide this function the tripper needs to be controlled

in such a way as to maintain the safety standards set out in AS1755. A list of specific

tripper controls and switches is given below:

Local Control Panel (LCP)Remote Control Panel (RCP)Tripper Position Switch (TPS)Tripper Travel Limit (TTL)Level Sensor (LS)

6.5.1 Local Control Panel

Much like a normal conveyor the tripper has a local control panel, however because the

tripper is reversible it has an extended local control panel as mentioned previously.

6.5.2 Remote Control Panel

The remote control panel is not a standard feature for conveyors. For specific

operational requirements Karara has requested that remote control be incorporated into

the design of the tripper. This will allow the operators to move the tripper into position

manually before discharging the minerals.

The remote control system comprises of a remote control transmitter and a receiver. The

receiver is connected to the digital inputs so that it may relay the required commands

back to the PLC. The E/Stop is also hardwired from the remote control receiver into the

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hardwire circuit. The remote control receiver does not have the local/auto selection

because that control is on the local control panel. When the remote is being used the

local control panel 2-position switch will be set to local control and when it is not being

used the tripper will function on auto.

Figure 2: Remote Control Panel Receiver

6.5.3 Tripper Position Sensor

In order for the tripper to position itself to discharge the minerals it uses a tripper position

sensor. The reason for positional discharge is to prevent discharge of minerals onto the

structural frame supporting the tripper.

The tripper position sensor is a magnetic proximity sensor that is attached to the tripper.

Metal flags are mounted to the conveyor so that the tripper position sensors send a

signal when aligned with the flags. The tripper position flags are shown in drawing 1681-

EL-DRG-1283 in Appendix A – KIOP Electrical Drawings.

6.5.4 Tripper Travel Limit

The tripper travel limit is a protective stop control although not every tripper travel limit will

stop the conveyor. The majority of the tripper travel limits are used as a signal of position

to the PLC. This is required to convert any progressive position errors which would

otherwise occur with the tripper position sensor system. The application of tripper travel

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limits at each end is different because one end of the conveyor will have a service bay for

the tripper and the other will not. For the Following sections please refer to drawing

1681-EL-DRG-1283 in Appendix A – KIOP Electrical Drawings.

At the head end of the conveyor there are three tripper travel limits; one provides a signal

that the tripper has entered the service area (TTL3), another to indicate the tripper is in

position to be serviced (TTL2) and the final is a protective stop tripper travel limit to

indicate that the tripper has travelled too far and should be stopped immediately (TTL1).

TTL4 is located half way along the conveyor to indicate to the PLC when the tripper has

passed the halfway mark of the conveyor. This is a precautionary measure that is used

in conjunction with the tripper position sensor to confirm the trippers exact position.

At the tail end of the conveyor TTL5 indicates to the PLC that the tripper has reached the

end of the conveyor and that it should stop. If the tripper does not stop TTL6 will be

tripped and will disengage the tripper. TTL1 and TTL6 are part of the hardwired circuit to

physically stop the motor.

6.5.5 Ultrasonic Level Sensor

The ultrasonic level sensor (ULS) is used to measure the height of the minerals stockpile.

Two ULS devices are attached to the tripper and communicate via Modbus back to the

PLC. DeviceNet was considered but the length of cable is limited at the required data

rate.

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Figure 3: Ultrasonic Level Sensor

6.5.6 Catenary Snag Sensor

The catenary snag switch is a sensor that indicates to the PLC that the catenary has

been snagged while in motion. The Tripper will then be stopped to prevent any damage

to the catenary or the cable running through it. The catenary snag sensor will be vendor

supplied with the catenary.

6.6 Dust Suppression

AS1755 also covers the requirements of dust suppression around conveyors. The

transfer points are of particular interest as this is where most dust is generated. Transfer

points include conveyor to conveyor and tripper to stockpile. The dust suppression

methods are different for each.

6.6.1 Dry Dust Controller

Dust suppression at the conveyor to conveyor transfer points consists of dust extraction

fans that remove and collect the dust. The dust extraction fans may range from 30kW to

200kW in size depending on the area where extraction is required. The dust controllers

have a local control panel and isolator much like the other equipment on the premises.

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6.6.2 Wet Dust Controller

Wet dust controllers are used at the tripper to limit the amount of dust created during

material transfer. The following instruments and controls are used:

Master Catenary Water Supply Solenoid (CSV)Dust Suppression Solenoid (DSS)Water Spray Sensor (WSS)

6.6.2.1 Master Catenary Water Supply Solenoid

The master catenary water supply solenoid controls the water supply to the tripper. In

the event of a burst pipe the master catenary water supply solenoid will shut off the

water.

6.6.2.2 Dust Suppression Solenoid

The dust suppression solenoid activates the water supply to the foggers that create a fine

mist spray that is used to reduce the excess dust created by the material discharge. The

tripper has two fogger sets, one on the front and one at the rear.

6.6.2.3 Water Spray Sensor

The Water spray sensor is a magnetic proximity sensor that is used in the same manner

are the tripper position sensor. Flags indicate that the tripper has reached the position

where the DSS needs to be turned off to prevent excess water collecting on the structural

framework.

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7.0 Electrical Design

The electrical design team on the KIOP project is considered a supporting discipline; their

role is to provide the necessary electrical design to complement the overall structural and

mechanical design. The mechanical department produces much of the information

required in electrical design. Good examples of this are the motor sizes required for the

conveyors, where the mechanical department will size the motor and give that

information to the electrical department to fill in the rest of the electrical design.

Different areas of concern to the electrical engineers are:

High Voltage SupplyTransformerLow Voltage Distribution

These aspects are discussed in the following sections.

7.1 High Voltage

The high voltage design consists of a feed from the Western Power incomer that

connects to two transformers (each 2MVA). Power from these transformers will supply

almost all of the stage 1 design. Conveyor CV702 will be the exception, due to the large

distance between the transformers and the CV702 motor. CV702 will be fed from

existing infrastructure.

The transformer sizes were determined by the maximum demand calculation that

estimates the total load on the electrical system. The loads are determined by a

schedule that specifies what equipment will be active. The loads are then totalled so that

the schedule will indicate which operating process will determine the maximum demand.

Unfortunately, the intern played no part in designing the HV system although there was

an opportunity to review the documents in order to become familiar with the project as a

whole.

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7.2 Single Line Diagrams

The single line diagram provides a summary of all the electrical equipment that is

connected to the motor control centres. The large equipment have individual

connections whereas distribution boards (DB) feed the smaller equipment.

The motor control centre (MCC) manufacturers generally use the information shown on

the single line diagram as it indicates: the number of connections, busbar size, fault

levels, cable sizes (to allow for proper termination) and circuit breaker sizes that are

required.

The intern was involved in many but not all of the aspects of the single line diagram

design. The relevant aspects are listed below:

Updating the single line diagram with load informationCable sizingCircuit breaker sizingLoad balancing

Aspects that were designed without the intern’s involvement are listed below:

Busbar sizingFault calculations

The following sections discuss the intern’s involvement in designing the single line

diagram.

7.2.1 Updating the Single Line Diagram

To update the single line diagram, the load information was retrieved and was marked up

on the single line diagram; specifying the load type (motor or DB), current requirement

and connection type from the MCC to the load. Refer to the drawings listed in Table 1:

Single Line Drawing List in Appendix A – KIOP Electrical Drawings.

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Table 1: Single Line Drawing List

Drawing Number Drawing Title1681-EL-DRG-1342 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 1 of 41681-EL-DRG-1343 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 2 of 41681-EL-DRG-1344 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 3 of 41681-EL-DRG-1345 Hematite Shed - MCC - HEM001; Single Line Diagram; Sheet 4 of 4

The connection could be one of four types on KIOP:

Variable speed drive (VSD)Direct online (DOL)Feeder Module (ELR)

7.2.1.1 VSD

A VSD is a method of controlling the power delivered to a motor and therefore controlling

the motor. The VSDs used on KIOP are Telemecanique Altivar 71 devices that range

from 2.2kW to 280kW. A VSD is used for its ability to ramp up the current upon starting

to prevent large motor starting currents. The ability to reduce power output for stopping

the motor is also an attractive function.

A function that is not being used is that of precise speed control. There has been no

encoder type feedback control mechanism provided, although it would be possible to

incorporate this function in future upgrades.

Upstream from the VSD is a circuit breaker that has a magnetic trip that is designed to

protect against cable fault conditions. The circuit breaker is an Allen-Bradley 140M type

and all technical information is taken from the Allen-Bradley website.

7.2.1.2 Direct Online

The DOL is a starting technique that applies either the full power, or no power. There are

no ramp times. The DOL has an electronic overload (EOL) module that monitors the

circuit and load integrity. The electronic overload is also connected to the PLC and is

able to send signals reporting errors over Devicenet. The DOL can also be controlled via

the electronic overload as shown in drawing 1681-EL-DRG-1696 in Appendix A – KIOP

Electrical Drawings.

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The circuit breaker used for the DOL devices has a thermal and magnetic trip. This

allows the circuit breaker to protect in a fault and in overload conditions. The circuit

breaker is an Allen-Bradley 140UE type.

7.2.1.3 Feeder Module

The earth leakage relay uses a current transformer (CT) that measures the residual

current across the active and neutral conductors. The ELR allows the current level and

the time delay to be set, therefore reducing the need to size the cables for earth loop

impedance (discussed in section 6.2.2).

7.2.2 Cable Sizing

Cable selection is based on 3 main criteria; current carrying capacity, voltage drop and

short circuit conditions. AS3008 sets out the method of selecting cables by these criteria

for cables below 1kV. AS3000 introduces an earth parameter, namely earth fault-loop

impedance.

As part of the internship, there was a need to create all the cable calculations for the

single line diagram using the AS3008 and AS3000 standard design. The cable sizes are

shown on the single line diagram listed in Table 1: Single Line Drawing List. Examples of

the cable calculations are given in Appendix H – Cable Calculation Examples.

The cable calculation sheet that was used, was created by the intern to make the tedious

task of cable calculation quicker and to reduce errors in the calculations. The power of

the calculation sheet comes from the calculations being executed by visual basic for

applications (VBA).

7.2.2.1 Current Carrying Capacity

Selection of cables based on current takes into account the external conditions and the

installation of the cables. Focus is primarily on the thermal rating of the cable.

Depending on the type of installation, ambient temperature and number of circuits a

derating factor is applied to the current required by the load. The derated current is then

used to select the cable size.

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7.2.2.2 Voltage Drop

This section in AS3008 is a result of the AS3000 requirement that the voltage not drop

more than 5% at the source of the low voltage supply, (i.e. from the transformer to the

motor, the volt drop cannot be more than 5%).

The voltage drop can be calculated using the AS3008 procedure of calculating the mV

drop per A.meter and finding the corresponding table on standard cable volt drops. The

volt drop can also be calculated using first principles V=I*R.

7.2.2.3 Short Circuit

The short circuit calculation determines the maximum allowable let through energyduring

a fault. The cable should not be damaged due to the let through energy. The short

circuit is based on the fault current and the time taken for the circuit breaker to trip.

7.2.2.4 Earth Fault-Loop Impedance

Earth fault-loop impedance is found in AS3000 and should be considered in the

calculation of cable sizes. Essentially the larger the conductor the smaller the resistance

and therefore the larger the current in the event of an earth fault. If the earth loop

resistance is too large then the fault current will not be as large and may cause the circuit

breaker not to trip quickly enough.

The size of the conductors involved will determine the maximum earth loop length and

therefore limit the total length from the source to the load. The calculation for the earth

loop can be found in Annexure B of AS3000.

7.3 Switchroom

The switchroom houses the MCC, VSD panels and the PLC tier. The MCC has incomers

from the transformers that connect to busbars that are used to connect to all the other

equipment. As mentioned previously the MCC manufacturers will use the single line

diagram to determine the requirements for the MCC panel. Refer to drawing 7539405-

50402 in Appendix B – GPA Drawings

The VSD panels house all the VSDs that are fed from the MCC and one rack for the

associated PLC. Each VSD size plays a part in the design of the VSD panel as there are

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standard modular racks and the VSDs are arranged to achieve the smallest possible

VSD panel. It is also required that additional space is allowed for future expansions,

normally 20% extra space.

Internal to each rack are the VSD and associated equipment. Refer to the general

arrangement drawing from GPA 7539405-50414 of the VSD rack from the GPA in

Appendix B – GPA Drawings.

7.3.1 Schematic

The schematic diagram is produced to provide information about the VSD or DOL to the

electrical installers and MCC switchboard manufacturers. The intern was asked to

maintain, update and check the schematics. Below are the VSD and DOL schematics

and the relevant points on each. Refer to drawing 1681-EL-DRG-1371 for the VSD

schematic and 1681-EL-DRG-1696 for the DOL in Appendix A – KIOP Electrical

Drawings.

The right hand side of the schematic drawing shows a summary of the instrumentation

that is associated with that piece of equipment. This part of the schematic is normally

used when the PLC is being coded (discussed in section 6.4.3).

7.3.1.1 VSD Connections

The example of CV703 is used to show what is done when the conveyor has more than

one associated VSD. The VSD operates in much the same manner except that one VSD

is the master and the other the slave. This allows for the VSDs to work together with

more efficiency.

The information on the left hand side of the schematics shows: the incoming three phase

active conductors, neutral and earth, circuit breaker, contactor, VSD or electronic

overload device, isolator and then the connection to the load. The schematic also shows

the connections available on the VSD/DOL device and where they are connected.

The VSD is supplied with 24V DC from the 24V DC distribution single line. This 24V is

used to power the indicator lights and small relays. The 24V also connects to the

hardwire circuit that connects to: the local control panel E/Stop, ISO and the pull wire

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switch. Any additional hardwire requirements are wired in series to these devices. 24V

DC is used, due to its safe operating voltage, for personnel safety.

Once the drive has received the “get ready” command from the PLC relay R2 closes.

This supplies power to K27 relay. Once K27 is active the secondary relay K27-1 closes

which, provided the circuit breaker is closed, provides power to the K15 relay that closes

the contactor supplying power to the VSD (K127 is the second motor relay, this would not

normally be shown for a single VSD). At this stage the R1 relay is closed to indicate that

the VSD is ready to start to output power to the motor. In the event of a fault the R1 relay

will become de-activated. This will also deactivate the R2 relay because the R1 and R2

relays share a software variable and therefore are “interlocked”.

K15 also has a secondary contact that is used as an input to the VSD to signal that the

main contactor has been closed. The main circuit breaker also has a secondary auxiliary

contact that is connected to an input into the VSD to confirm that there is power available

to the VSD.

While the motor is not running the motor heaters are active to prevent condensation. The

K35-1 relay is a normally closed relay that draws power upstream from the VSD

contactor. When the VSD is ready and starts to output power to the motor, relay LO4 is

activated thereby indicating that the VSD drive is now running and simultaneously

activating the K35 contactor to de-energise the motor heater (K135 is the second motor

relay, this would not normally be shown for a single VSD).

There are also motor temperature alarm and trip inputs (thermistor) to the VSD (TH1 and

TH2). When the alarm thermistor is activated a signal is sent to the PLC to indicate the

temperature. Then the trip thermistor is activated then the VSD will cease operation to

prevent damage to the motor.

At the bottom of the schematic the connection to Devicenet with a future connection to

Modbus is available.

The intern’s role in regards to the schematics was to become familiar with the VSDs by

reading the VSD programming manual. This manual outlines the capable functions of

the VSD. Once familiar with the VSDs the intern then moved on to check all the

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schematics to ensure that they were correct and that the hardwire circuit was correct. A

list of drawings that were checked and updated where necessary are given in Table 2:

VSD Schematics Drawing List and can be found in Appendix A – KIOP Electrical

Drawings.

Table 2: VSD Schematics Drawing List

Drawing Number Drawing Title1681-EL-DRG-1362 Conveyor CV702; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1363 Conveyor CV702; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1371 Conveyor CV703; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1372 Conveyor CV703; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1382 Conveyor CV704; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1383 Conveyor CV704; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1586 Conveyor CV704 Shuttle; Schematic Diagram - VSD1681-EL-DRG-1392 Conveyor CV705; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1393 Conveyor CV705; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1401 Tripper TP705; Schematic Diagram - VSD; Sheet 1 of 31681-EL-DRG-1604 Tripper TP705; Schematic Diagram - VSD; Sheet 2 of 31681-EL-DRG-1402 Tripper TP705; Schematic Diagram - VSD; Sheet 3 of 31681-EL-DRG-1414 Belt Feeder BF517; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1415 Feeder BF517; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1421 Feeder FE518; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1422 Feeder FE518; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1428 Feeder FE519; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1429 Feeder FE519; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1434 Conveyor CV520; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1435 Conveyor CV520; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1443 Conveyor CV521; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1444 Conveyor CV521; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1452 Conveyor CV522; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1453 Conveyor CV522; Schematic Diagram - VSD; Sheet 2 of 21681-EL-DRG-1461 Conveyor CV523; Schematic Diagram - VSD; Sheet 1 of 21681-EL-DRG-1462 Conveyor CV523; Schematic Diagram - VSD; Sheet 2 of 2

7.3.1.2 DOL Connections

The direct online schematic is very similar to the VSD schematic, however instead of a

VSD there is an electronic overload device. The power is supplied in much the same

manner: through the circuit breaker, contactor, electronic overload, isolator and then the

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motor. The hardwire circuit is also the same, 24V supplied from the 24V distribution

through the E/Stop and isolator.

The “trip” relay internal to the direct online device will be normally closed and therefore

when there is no fault the drive ready light will be active as well as supplying the “out-A”

relay with 24V DC which is used to close the activate the relay K27 that activates the

main contactor K16. Once K16 has been activated power will be supplied to the motor.

The direct online device also uses the relay “out-B” to indicate a fault condition that will

deactivate the “out-A” relay.

The direct online device also takes three input signals that indicate: circuit breaker status,

main contactor status and 24V supply status. There is also a connection to Devicenet.

The intern’s duties with the DOL schematics was the same as the VSD schematics. A list

of direct online schematics is given in Table 3: DOL Schematic Drawing List and can be

found in Appendix A – KIOP Electrical Drawings.

Table 3: DOL Schematic Drawing List

Drawing Number Drawing Title1681-EL-DRG-1408 Hematite Storage Shed; Ventilation Scrubber Unit 1 SB705A; Schematic Diagram - VSD1681-EL-DRG-1410 Hematite Storage Shed; Ventilation Scrubber Unit 2 SB705B; Schematic Diagram - VSD1681-EL-DRG-1412 Dust Collector - DC503; DOL Schematic Diagram1681-EL-DRG-1696 Dust Collector - DC521; DOL Schematic Diagram1681-EL-DRG-1706 Dust Collector - DC522; DOL Schematic Diagram

7.4 Instrumentation and Control Pack

The instrumentation and controls pack is made up of four parts; instrumentation and

controls layouts, connection diagrams, hardwire drawings and the left hand side of the

schematic. A list of example drawings are given in Table 4: Example of instrumentation

and controls Pack Drawings from Appendix A – KIOP Electrical Drawings and will be

used in the following sections.

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Table 4: Example of instrumentation and controls Pack Drawings

Drawing Number Drawing Title1681-EL-DRG-1375 Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1376 Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1377 Junction Box CV703-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1378 Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1379 Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1380 Junction Box CV703-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1275 Conveyor CV703; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1276 Conveyor CV703; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1381 Conveyor CV703; Hardwired Connection Diagram

7.4.1 Instrumentation and Controls Layout

The instrumentation and controls layouts are created to provide the instrumentation

installers with an overall view of the conveyor and its associated equipment. The layout

also provides the approximate locations of the instrumentation, although the locations are

not exact. Refer to drawings 1681-EL-DRG-1275 and 1681-EL-DRG-1276 in Appendix A

– KIOP Electrical Drawings.

In order to show the locations of the instrumentation two views are needed of the

conveyor; plan and elevation. The plan and elevation are created by taking a “cut” of the

3D model. The 3D model is created by the structural and mechanical designers, who

produce a scale model of the entire project.

Once the drawings have been created the instrumentation can be added. In order to

keep track of all the instruments for each conveyor a register was created. The register

was then used to help populate the plan and elevation drawings. As well as to ensure

sufficient inputs and outputs are available.

The intern’s role in the instrumentation and controls layout was to populate all the

instrumentation layouts. The intern was not required to become acquainted with the

instrumentation nor provide a design. For example, the pull wire switches are required to

be spaced 100m from the main device to an end support. In some instances the

distance was decreased because the length to be covered was too long and therefore

required more pull wire switches.

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The intern was also required to provide intelligent placement of the equipment so that the

access way was not reduced to a width smaller than that allowed by the standard

(600mm). Some conveyors only had personnel access to one side of the conveyor and

therefore did not require a pull wire switch on the non-accessible side (AS1755).

The drawings that populated in the intern, as part of the instrumentation and controls

layout pack are listed below in Table 5: Instrumentation and Controls Drawing List

Table 5: Instrumentation and Controls Drawing List

Drawing Number Drawing Title1681-EL-DRG-1271 Conveyor CV702; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1272 Conveyor CV702; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1275 Conveyor CV703; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1276 Conveyor CV703; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1279 Conveyor CV704; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1280 Conveyor CV704; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1283 Conveyor CV705; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1284 Conveyor CV705; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1287 Tripper TP705; Instrumentation & Controls; General Arrangement1681-EL-DRG-1288 Belt Feeder BF517; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1289 Belt Feeder BF517; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1292 Belt Feeder BF518; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1293 Belt Feeder BF518; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1296 Belt Feeder BF519; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1297 Belt Feeder BF519; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1317 Conveyor CV520; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1318 Conveyor CV520; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1325 Conveyor CV521; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1326 Conveyor CV521; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1329 Conveyor CV522; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1330 Conveyor CV522; Instrumentation & Controls; General Arrangement Elevation1681-EL-DRG-1333 Conveyor CV523; Instrumentation & Controls; General Arrangement Plan1681-EL-DRG-1334 Conveyor CV523; Instrumentation & Controls; General Arrangement Elevation

7.4.2 Connection diagram

The connection diagrams serve three purposes: show the contents of the junction box

(JB), show the physical wiring of the equipment in the JB and assist the controls system

integrators to tag all equipment so the communications network operates correctly.

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There are four types of connection diagrams currently used on KIOP, digital inputs, digital

outputs, pulse counters and analog outputs.

7.4.2.1 Digital Input

The digital input diagrams generally have two drawings to show all the connections. This

is because the digital input cards have 32 inputs and it is very difficult to fit 32

instruments onto one A3 page. Though the digital input diagrams are generally very

similar, there are some exceptions. One such exception is that of the tripper. Because

the conveyor and the tripper both have a JB, the emergency instrumentation from either

is required to stop the other and vice versa. Refer to drawings 1681-EL-DRG-1403 and

1681-EL-DRG-1404 in Appendix A – KIOP Electrical Drawings.

The digital input diagram is broken up into two parts, the junction box and the field.

These sections are self explanatory but it should be noted that the digital input diagrams

do not give any indication of required cable lengths. That information can be obtained

from the instrumentation and controls layouts.

At the top left of the diagram is the power supplied by the 240V distribution network. The

240V feeds a terminal strip, then a power supply converts the 240V into a 24V DC

supply. The 24V DC supplies a terminal strip called “internal connections” which is used

to supply the rest of the JB. Each 24V supply from the internal connection terminal strip

has a small circuit breaker to isolate the faulty device to allow the rest of the JB to

operate. The “internal connections” terminal strip supplies power to the digital input

module (Allen-Bradley 1794-IB32), digital output module (1794-OB8EP), ControlNet

adapter (1794-ACN15) and the terminal block DI.

The terminal block DI has four separate power supplies to the terminal block DI, this is to

prevent losing all the digital inputs if a fault occurs. This configuration will allow 24 inputs

to remain if there is a fault on a single group of 8 inputs.

At this point the digital input is the same for most of the conveyors. Devices that are

unique to the tripper are the pull wire switch relay, remote control panel and the bypass

relay.

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The pull wire switch relay has been added to comply with the safety requirements of

AS1755. If there is an emergency and a pull wire switch is pulled then both the conveyor

and the tripper need to stop. So the pull wire relay monitors both hard wire circuits and

will trip both VSDs if either circuit is interrupted. This is evident on the tripper and CV705

schematic drawings 1681-EL-DRG-1392 and 1681-EL-DRG-1401 in Appendix A – KIOP

Electrical Drawings.

The bypass relay has been designed so that the inputs from the remote control receiver

are not received when the conveyor is set to automatic control. This is to prevent any

unintentional stops or disruptions to the conveyor. The bypass relay is controlled by the

digital output module, which sets the status of the relay. The relay then acts as a

gateway for digital input and digital output signals.

The field side of the connection diagram has the symbols of the instruments that are

connected in the field. The instruments are connected to the right hand side of the

terminal block DI which is connected to the digital input module. In some cases the

instruments are not shown on the diagram because they have connections to other

modules. The remote control panel is an example of this, it is connected to the digital

input but is shown on the digital output diagram. In this situation a reference is given to

the appropriate drawing.

7.4.2.2 Digital Output

The digital output module has many of the characteristics of the digital input diagrams.

The output module is supplied with power from the same power supply, has 8 outputs

and sends digital output signals to a similar terminal strip. Refer to drawing 1681-EL-

DRG-1405 in Appendix A – KIOP Electrical Drawings.

7.4.2.3 Pulse counter

The pulse counter module is used for the belt feeders only. The other conveyors have an

under-speed relay that signals the under speed, but the pulse counter reads the speed of

the belt continuously. The power for the pulse counter is supplied from a separate power

supply to prevent any interference from the other modules. Refer to drawing 1681-EL-

DRG-1419 in Appendix A – KIOP Electrical Drawings.

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7.4.2.4 Analog Output

The analog output is used to display the outloading rate of the conveyor system to the

front end loaders. Each feeder is allocated a digital display unit that receives an analog

signal from the analog output unit 1749-OF41. Refer to drawing 1681-EL-DRG-1448 in

Appendix A – KIOP Electrical Drawings.

7.4.2.5 Internship Contribution

The intern was asked to become familiar with the above mentioned drawings and to

populate the drawings with all the instruments for each conveyor. In some circumstance

the quantity of instrumentation associated with a conveyor is minimal therefore there is

wasted space in the JB. In these cases the instrumentation from one conveyor had been

included on another connection diagram. This can be seen in drawing 1681-EL-DRG-

1448 in Appendix A – KIOP Electrical Drawings, that show the tail end instrumentation for

CV521 and the head end instrumentation of CV520 in the same digital input drawings.

As well as populating the instrumentation on the drawings, the intern was required to

revise the electrical design of the connection diagrams to ensure that they met the design

requirements given to Maunsell. A list of the connection diagram drawings is given in

Table 6: Connection Diagram Drawings and the drawing are given in Appendix A – KIOP

Electrical Drawings.

Table 6: Connection Diagram Drawings

Drawing Number Drawing Title1681-EL-DRG-1364 Junction Box CV702-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1365 Junction Box CV702-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1366 Junction Box CV702-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1367 Junction Box CV702-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1368 Junction Box CV702-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1369 Junction Box CV702-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1375 Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1376 Junction Box CV703-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1377 Junction Box CV703-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1378 Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1379 Junction Box CV703-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1380 Junction Box CV703-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1384 Junction Box CV704-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1385 Junction Box CV704-JBT; Digital Input Module; Connection Diagram Sheet 2 of 2

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1681-EL-DRG-1386 Junction Box CV704-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1394 Junction Box CV705-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1395 Junction Box CV705-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1396 Junction Box CV705-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1397 Junction Box CV705-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1398 Junction Box CV705-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1399 Junction Box CV705-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1403 Junction Box TP705-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1404 Junction Box TP705-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1405 Junction Box TP705-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1406 Junction Boxes TP705; Connection Hardwired Diagram1681-EL-DRG-1416 Junction Box FE517-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1417 Junction Box FE517-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1418 Junction Box FE517-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1419 Junction Box FE517-JBH; Pulse Counter Module; Connection Diagram1681-EL-DRG-1423 Junction Box FE518-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1424 Junction Box FE518-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1425 Junction Box FE518-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1426 Junction Box FE518-JBH; Pulse Counter Module; Connection Diagram1681-EL-DRG-1625 Junction Box BF518-JBH; Analog Output Module; Connection Diagram1681-EL-DRG-1430 Junction Box FE519-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1431 Junction Box FE519-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1432 Junction Box FE519-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1433 Junction Box FE519-JBH; Pulse Counter Module; Connection Diagram1681-EL-DRG-1439 Junction Box CV520-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1440 Junction Box CV520-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1441 Junction Box CV520-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1445 Junction Box CV521-JBH; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1446 Junction Box CV521-JBH; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1447 Junction Box CV521-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1448 Junction Box CV521-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1449 Junction Box CV521-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1450 Junction Box CV521-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1457 Junction Box CV522-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1458 Junction Box CV522-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1459 Junction Box CV522-JBT; Digital Output Module; Connection Diagram1681-EL-DRG-1463 Junction Box CV523-JBH; Digital Input Module; Connection Diagram - Sheet 1 of 21681-EL-DRG-1464 Junction Box CV523-JBH; Digital Input Module; Connection Diagram - Sheet 2 of 21681-EL-DRG-1465 Junction Box CV523-JBH; Digital Output Module; Connection Diagram1681-EL-DRG-1466 Junction Box CV523-JBT; Digital Input Module; Connection Diagram Sheet 1 of 21681-EL-DRG-1467 Junction Box CV523-JBT; Digital Input Module; Connection Diagram Sheet 2 of 21681-EL-DRG-1468 Junction Box CV523-JBT; Digital Output Module; Connection Diagram

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7.4.3 Schematic

The schematics also provide information about the instrumentation and controls pack.

Each device will have associated instrumentation which is summarised in the right hand

side of the schematic drawing.

7.4.3.1 Right Hand Side

The right side of the schematic shows the source, terminals, instrument symbol and then

the digital input or output. This information is normally used by the PLC programmers so

that the correct instrumentation is associated with the correct device. Almost all the

information shown on the connection diagrams are shown in the schematic summary.

Refer to drawing 1681-EL-DRG-1696 in Appendix A – KIOP Electrical Drawings.

7.4.3.2 Tripper

The tripper is slightly different because there is instrumentation on the tripper itself and

therefore has a terminal box on the tripper to connect the instrumentation to the JB.

Referring to drawing 1681-EL-DRG-1604 in Appendix A – KIOP Electrical Drawings.

This schematic shows the summary of the instrumentation that is attached to the tripper

physically. In order to run the cables to the tripper, the cables enter JB1 and then run

along the catenary to JB2 then to the instrumentation and return through JB2 and JB1.

7.4.3.3 Internship Contribution

Once the connection diagrams were updated, the schematic instrumentation summary

could be populated. The schematics were populated with all the instrumentation as listed

in Table 2: VSD Schematics Drawing List.

The tripper schematic 1681-EL-DRG-1604 was created using a previous project drawing

as a template, which the intern modified it to suit the KIOP project.

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8.0 Lighting Design

The main priority for the lighting is to provide the required luminance to all working areas

so that normal work, maintenance and repairs can be performed. The lighting should

also provide safe egress from the buildings in the event of an emergency (AS1755).

AS1755 refers to AS1680 Interior and Workplace Lighting to provide the benchmark for

the lighting in and around conveyor systems.

AS1680 is specific about the minimum level of light (lux) and the uniformity of the light

required over an area to perform different tasks. Uniformity of light is defined as the ratio

of the minimum lighting level and the average lighting level for a set surface area

(AS1680.0, 1998). A summary of the main benchmark data used in the lighting design is

given below in Table 7: Lighting Levels from AS1680.

Table 7: Lighting Levels from AS1680

Minimum illuminance 20 lux AS1680.0Minimum illuminance uniformity 0.3 AS1680.0Minerals Handling

Conveyor gantries 40 lux AS1680.2.4 Transfer houses 80 lux AS1680.2.4

Switch room 160 lux AS1680.2.1

The intern was asked to produce the lighting design pack for KIOP stage 1. The lighting

design for stage 1 includes internal and external lighting for:

All conveyor gallery lighting

The storage shed

The MCC and transformer compound

All transfer towers and take-up towers

The first stage in the design process was to produce some computer simulated models

that would give standard distribution of light fittings that would provide the required

amount of light for safe functionality. The lighting modelling was done on a program

called AGI32 and four models were produced as templates; switchroom, CV520, TT523

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and CV702 (standard conveyor gallery). General areas where lighting is required are

discussed below.

8.1 Conveyor Galleries

The conveyor gallery, was simply modelled as a rectangular room with a rectangular

column running horizontally to simulate the conveyor. The reason a solid column was

used is that AS1680 calls for the lighting to be on access ways. Once the room and

objects have been setup the light fixtures are added. This process was trial and error for

the intern because there is little restriction on design laid down by AS1680 except the

minimum requirement.

First, the intern modelled the lighting with single tube fittings and it was found that the

required spacing was quite close and the number of fixtures quite high. This was not

desirable because the extra fittings would cost more money and because the time taken

to install them would use extra man-hours (increasing cost). There was also opportunity

to have too much light therefore more light fixtures than required, which required more

cable to supply power. More power requires a bigger distribution board, larger quantity of

cables, higher energy bills and ultimately cost more money. Therefore meeting the

required standard will not only provide a safe working environment but also minimise

costs.

In order to reduce the number of light fixtures placed along the galleries a double fitting

was used in the simulation. This provided a larger spacing between the light fixtures

therefore requiring few fixtures and still met the requirements of AS1680.

An advantage of the layout of the galleries is that the conveyor galleries are a standard

design and therefore only require one model to determine the fixture spacing needed.

Once the spacing is determined it can be applied to all the galleries. See Figure 4:

Standard Conveyor Lighting Design Plan, Figure 5: Standard Conveyor Lighting Design

Isometric and Figure 6: Standard Conveyor Lighting Design Rendered Model below of

the lighting model for the conveyor galleries.

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Figure 4: Standard Conveyor Lighting Design Plan

Figure 5: Standard Conveyor Lighting Design Isometric

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Figure 6: Standard Conveyor Lighting Design Rendered Model

While most of the conveyors are very similar a few are different. In particular, conveyor

CV520 does not have an enclosed gallery around it because it is located inside the shed.

A factor that increases the complexity of design is the structural steel located to one side

of the walk way, protruding from the walls. This poses a problem for wall mounted light

as the steel will block the light from reaching all areas.

The computer model does not of the whole conveyor but a section, in order to gather

spacing information to be applied to the whole conveyor. During the design process Iit

was discovered that some dark corners were created by the steel structures and this led

to increasing the number of fixtures along the walls to provide the required lighting level.

See Figure 7: Conveyor CV520 Lighting Design Plan, Figure 8: Conveyor CV520 Lighting

Design Isometric and Figure 9: Conveyor CV520 Lighting Design Rendered Model below

of the lighting model for conveyor CV520.

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Figure 7: Conveyor CV520 Lighting Design Plan

Figure 8: Conveyor CV520 Lighting Design Isometric

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Figure 9: Conveyor CV520 Lighting Design Rendered Model

8.2 Transfer Towers

The model for the transfer towers was produced after completing the conveyor gallery

design and therefore progressed straight to the double fitting. The transfer towers are all

different and therefore would require a separate model for each to model the lighting

exactly. However, while using the lighting simulator the intern was able to see the

lighting levels around the fixtures and use that information to design the lighting for the

different transfer towers without running a simulated model for each. See TT523 Figure

10: Transfer Tower Lighting Design Plan, Figure 11: Transfer Tower Lighting Design

Isometric and Figure 12: Transfer Tower Lighting Design Rendered Model below of the

lighting model for the transfer tower.

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Figure 10: Transfer Tower Lighting Design Plan

Figure 11: Transfer Tower Lighting Design Isometric

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Figure 12: Transfer Tower Lighting Design Rendered Model

8.3 MCC and transformer compound

The lighting requirements for the switch room were much the same as the previous

lighting designs but with an added requirement; that the lighting levels should be taken

into account where the work would be conducted. In the case of the switch room, the

lighting levels on the face of the MCC and VSD panels should be at the required lux level

(AS1680). A similar design process to the transfer tower design was used for the switch

room. Lighting for external areas of the shed and the transformer compound have been

designed using a previous project (Mount Gibson Iron) drawings as templates. See

Figure 13: Switchroom Lighting Design Plan, Figure 14: Switchroom Lighting Design

Isometric and Figure 15: Switchroom Lighting Design Rendered Model below of the

lighting model for the Switch room.

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Figure 13: Switchroom Lighting Design Plan

Figure 14: Switchroom Lighting Design Isometric

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Figure 15: Switchroom Lighting Design Rendered Model

8.4 Storage Shed

The internal lighting for the storage shed will be designed by the lighting contractor as

part of the tender package.

8.5 Stairs and Handrail

The lighting design for the stairs and handrail has been taken from the MGI project. The

design has been previously approved and therefore can be used for KIOP.

8.6 Emergency lighting

To comply with AS1755, emergency lighting needs to be provided to any persons within

the structures in the event of an emergency in order for them to use a path to the exit of

that building. The design will be taken from the MGI lighting design.

8.7 Design Results

The modelling of the different areas provided results listed in Table 8: Lighting Design

Results.

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Table 8: Lighting Design Results

Area Result of simulation

Switchroom

In order to meet the requirements of AS1680 lights need to be

double globe XXX ceiling fixtures mounted parallel to the

MCC/VSD panels.

Conveyor galleriesSingle tube light fixtures mounted perpendicular to the conveyor

at 5m spacing to provide the required light on the walkway.

Conveyor CV520

All lighting is to be double globe and wall mounted parallel to the

conveyor. Spacing is to be XXX from the steel structure. Lights

below access ways are to be ceiling mounted with similar

spacing.

Transfer TowersLighting in the transfer towers is to be double globe and wall

mounted in most cases spaced by approximately 4m

StairsUsing MGI approved drawings, pole mounted lighting is to be

placed at the top and bottom of stairs.

Handrail Mounts All hand rail mountings to be single globe and spaced 3m.

Emergency lighting

All pole mounted light fixtures at stairs are to be emergency.

The general design theory is to make every second light fixture

(wall or ceiling) an emergency fixture. However descression is

used in areas that are not standard areas. Emergency exit

fixtures are also to be mounted in such a way that they indicate

the closest exit.

8.8 Lighting and Small Power Drawings

Lighting drawings are produced to aid the lighting installers during installation. The

drawings are not intended to be exact and therefore the installer requires the approval of

the site superintendent before final locations are determined. The other component to

these drawings is that the small power is included in the drawings. Small power

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components include: general power outlets, welding outlets, three phase outlets, switch

locations and more. The Design requirements are given in Table 9: Power Design

Requirements and to see the symbols and descriptions please refer to the General

Legend in Appendix A – KIOP Electrical Drawings.

Table 9: Power Design Requirements

Equipment Design Requirements

General Power Outlet (GPO)The GPO’s will be spaced 60m. This limitation is in place to

allow the use of a standard 30m extension cable.

Welding Outlet

The welding outlets are to be located at both ends of conveyors

and anywhere else large 3-phase portable machinery is likely to

be used.

Switched OutletThe locations of the switched outlet are where more outlets may

required.

Drawings are required for every location that will require a light fitting or small power. A

complete list of drawing for stage 1 is given in Table 10: Lighting and Small Power

Drawing List, and drawings can be found in Appendix A – KIOP Electrical Drawings:

Table 10: Lighting and Small Power Drawing List

Drawing Number Drawing Title1600-EL-DRG-1076 General Legend; Lighting and Power1681-EL-DRG-1246 Hematite Storage Shed; Internal & External Lighting; General Arrangement Plan1681-EL-DRG-1247 Hematite Storage Shed; Internal & External Lighting; General Arrangement Elevation1681-EL-DRG-1339 Switchroom SR-HEM Lighting, General Power & Communication; General Layout1681-EL-DRG-1273 Conveyor CV702; Lighting & Power; General Arrangement Plan1681-EL-DRG-1274 Conveyor CV702; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1277 Conveyor CV703; Lighting & Power; General Arrangement Plan1681-EL-DRG-1278 Conveyor CV703; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1560 Take-Up Tower TU703; Lighting & Power; General Arrangement Plan1681-EL-DRG-1561 Take-Up Tower TU703; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1281 Conveyor CV704; Lighting & Power; General Arrangement Plan1681-EL-DRG-1282 Conveyor CV704; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1285 Conveyor CV705; Lighting & Power; General Arrangement Plan

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1681-EL-DRG-1286 Conveyor CV705; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1290 Belt Feeder BF517; Lighting & Power; General Arrangement Plan1681-EL-DRG-1291 Belt Feeder BF517; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1295 Belt Feeder BF518; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1294 Belt Feeder BF518; Lighting & Power; General Arrangement Plan1681-EL-DRG-1298 Belt Feeder BF519; Lighting & Power; General Arrangement Plan1681-EL-DRG-1299 Belt Feeder BF519; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1319 Conveyor CV520; Lighting & Power; General Arrangement Plan1681-EL-DRG-1320 Conveyor CV520; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1327 Conveyor CV521; Lighting & Power; General Arrangement Plan1681-EL-DRG-1328 Conveyor CV521; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1331 Conveyor CV522; Lighting & Power; General Arrangement Plan1681-EL-DRG-1332 Conveyor CV522; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1335 Conveyor CV523; Lighting & Power; General Arrangement Plan1681-EL-DRG-1336 Conveyor CV523; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1321 Tower TT503; Lighting & Power; General Arrangement Plan1681-EL-DRG-1716 Tower TT503; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1322 Transfer Tower TT521; Lighting & Power; General Arrangement Plan1681-EL-DRG-1725 Transfer Tower TT521; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1323 Transfer Tower TT522; Lighting & Power; General Arrangement Plan Sheet 1 of 21681-EL-DRG-1726 Transfer Tower TT522; Lighting & Power; General Arrangement Elevation1681-EL-DRG-1728 Transfer Tower TT522; Lighting & Power; General Arrangement Plan Sheet 2 of 21681-EL-DRG-1324 Transfer Tower TT523; Lighting & Power; General Arrangement Plan1681-EL-DRG-1727 Transfer Tower TT523; Lighting & Power; General Arrangement Elevation

In all cases the lighting general arrangement comes in pairs, a plan and an elevation.

The plan view will show all the levels of the structure as a different section and this may

lead to more than one plan drawing as in the case of transfer tower TT522. The

elevations show a side view of the structure and may sometimes show the internal

lighting and sometimes show only the external lighting. What is shown on the drawings

is dependent on how cluttered they are because the drawings are not useful if they are

not readable. A good example of this is transfer tower TT523 elevation.

The intern’s role during the lighting design process was to firstly model the lighting to get

nominal spacing for different areas. Then to advise the drafting department of all the

“cuts” that were needed. The “cuts” are taken from the 3D model to show the relevant

structures in the area where the lighting is to be installed. Once the cuts were returned,

they were populated as per all the above mentioned drawings with the required lighting

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and small power. Once the pack (plan and elevation of each cut) markup was complete

the drawings were returned to the drafting department to be drafted. The drawings were

then returned for checking and when the intern was satisfied, the drawings progressed

for approval to the electrical engineer.

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9.0 PLC Design

For safety and operational efficiency the Karara storage facilities will be controlled by a

PLC. Automation generally provides time saving which leads to money saving. This PLC

will be responsible for monitoring the field instruments for faults and operational

conditions, sending signals to field instruments to indicate the diagnosed fault, startup

and shutdown processes and communicating with the existing GPA port PLC.

In order for the PLC to collect all the required data it will need to interface with multiple

communication media: Ethernet, Devicenet, Modbus and ControlNet. The PLC will also

be required to communicate with different areas of the GPA. For these reasons the

same equipment will be used to allow minimal interfacing and commissioning

complications as well as leveraging a commonality of spare parts. Equipment currently

used by the GPA and MGI are in the Allen-Bradley industrial communications range.

The PLC selected for KIOP is the Allen-Bradley 1756-PA72/C. This PLC was selected

primarily for its large memory capacity and its strong performance capabilities. This

allows Karara to upgrade and expand without upgrading the PLC. In the sections to

follow, the different networks and general setup of the communications will be explored

9.1 Ethernet

All the port facilities PLC’s are connected to an Ethernet backbone communications

network that passes status tags to each other to start and stop operational processes.

This approach will be used for the Karara Iron Ore Project (KIOP) but will have a private

network for Karara’s communications and have an interface between the private network

and the GPA backbone network. The interface between the two networks will be through

a firewall to minimise the security risks. This dual network approach will allow Karara to

communicate with their equipment without adding traffic to the Ethernet backbone. A

simple graphical representation of the network is shown below in Figure 16: Ethernet

Network.

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Figure 16: Ethernet Network

9.2 Devicenet

Devicenet is the communications protocol used for communications between the PLC

and the MCC and VSD panels. Devicenet was not the first choice for the communication

medium but the selected VSD’s (Schneider Altivar 71) do not have the capability to

communicate via ControlNet.

Each unit contained in the MCC and VSD panels is connected to the PLC so that the

PLC may send signals to start and stop devices such as the variable speed drives (VSD),

soft starters (SS) or direct online drives (DOL). The network also allows for status

information to be sent back to the PLC from the drives within the MCC. The primary

function of this network is to control the start and stop sequences as well as controlling

the running speed of the conveyors. In most cases the conveyors are run at a set speed

(80% of capability) and seldom change their speed. There is one conveyor type that has

a more active speed controller and that is the Feeder conveyor. The Devicenet

communications will also be used in the event of an emergency to stop the conveyors.

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9.3 Modbus

Modbus has been is used on limited applications where specific equipment is required

and communicates via Modbus. The two devices that currently use Modbus are the

ultrasonic level sensors (ULS) and the Micrologic 6.0H power analysers. The Micrologic

6.0H is a sophisticated power analyser that can monitor frequency, power factor, circuit

breakers and much more at the low voltage incomer level. This information is then sent

back to the PLC.

9.4 ControlNet

All the field instruments require to be connected to the PLC in order for the PLC to gather

all the relevant information to operate the storage facilities in a safe and efficient manner.

ControlNet is specifically designed to be used in field instrument applications. It is

capable of transferring information at high speeds and over long distances.

Each conveyor’s junction box (generally two JB’s per conveyor) has a Flex I/O module

that communicates with the PLC Flex I/O module. Each Flex I/O has a back plane that

allows for different types of instrumentation modules to be connected. These modules

include digital input, digital output, analog input, analog output, pulse counter modules

and more. This allows for a very large variety of field instrumentation to be connected to

the Flex I/O module that collects all the data and communicates back to the PLC via

Controlnet. An example network is shown below in Figure 17: ControlNet Network.

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Figure 17: ControlNet Network

The devices shown in Figure 17: ControlNet Network are listed below (Allen-Bradley-A,

2004):

1756-PA72/C Allen-Bradley Processor1794-ACN Allen-Bradley Flex I/O Module1786-RPA Allen-Bradley Repeater Adapter1786-RPCD Allen-Bradley Repeater Module

In order for the ControlNet network to function correctly, it cannot have more than 121 s

delay throughout the network. Each device on the network provides a delay and

therefore the sum of these delays cannot be more than 121 s (Allen-Bradley-A, 2004).

For example the 1786-RPCD repeater module has a delay time of 100ns, the 1786-RPA

repeater adapter has a delay time of 901ns and fiber cable has a delay time of

5.01ns/m(Allen-Bradley-A, 2004).

9.5 Internship Contribution

During my internship I have been able to participate in the design of the communications

network. Specifically, I have been involved in:

Investigation of Network types and applicationsInvestigation of equipment requiredCreation of the network block diagram (Appendix A – KIOP Electrical Drawings –1681-EL-DRG-1353)Updating Schematics and Connection diagrams with communication networkinformation

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10.0 References

Allen-Bradley-A, (2004), ControlNet Fiber Media Planning and Installation Guide:

1786 Series, Rockwell Automation.

AS1680, (1998) Interior Lighting: Safe Movement, Standards Australia

AS1755, (2000), Conveyor – Safety Requirements: Third Edition, Standards:

Australia

AS3000, (2007), Wiring Rules: Fifth Edition, Standards Australia.

AS3008, (1998), Electrical Installations – Selection of Cable: Third Edition,

Standards Australia.

Data sheets provided as appendices are also references

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11.0 Bibliography

Merlin Gerin, (2006) LV Circuit Breakers and Switch Disconnectors: Compact NS,

Schneider Electric.

NHP, (2007) Price List Catalogue: Part B, NHP Electrical Engineering Specialists.

Telemecanique, (2007) Variable Speed Drives: Altivar 71 Catalogue, Schneider

Electric.

Telemecanique, (2007) Variable Speed Drives: Altivar 71 Programming Manual,

Schneider Electric.

Toshiba, (2008) Premium Efficiency Electric Motors, Toshiba.


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