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Professional Project

Commissioning of Electrical Equipment up to 11kV in Substations and Material Handling Machines

Commissioning of electrical equipment up to 11kV, including substations, switchgear, PLCs, and VFDs for material handling machines.

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🛠 Project Title: Commissioning of Electrical Equipment up to 11kV in Substations and Material Handling Machines

📍 System Overview: This project was part of a brownfield plant expansion involving the commissioning of a conveyor system and various material handling yard machines. The scope covered substations with HT and LT switchgear, transformers, and a diverse array of field equipment across a 11kV power distribution network.

👷 My Key Responsibilities:

  • Commissioning and testing of switchgear panels including: Incomers, Bus Couplers, Motor Feeders, Ground Isolators, Compressors, and Lighting Distribution up to 11kV.
  • Testing and modification of control circuits for site-specific logic.
  • Programming, commissioning, and testing of PLCs for yard machines.
  • Installation, tuning, and parameterization of VFDs for precise drive control.
  • Programming of motor protection relays for advanced fault protection.
  • Verification and commissioning of power and control circuits, ensuring all interlocks and protections worked as designed.
  • RF network design and deployment using modems, switches, and routers to enable wireless communication between mobile machines and land-based PLCs.
  • HMI development and deployment for touch-based control of mobile yard equipment.

🏗 Equipment Commissioned:

  • Material Handling Machines: Twin Boom Stackers (TBS), Wheel-On-Boom Reclaimers (WOBR), Blender Reclaimers (BRC), Wagon Tipplers (WT)
  • Electrical Infrastructure: 415V MCCs, 6.6kV HV MCCs, 11kV/6.6kV/415V Transformers, Lighting Distribution System

PLCs Programmed: Schneider M580, Siemens S7-300, Allen Bradley Micrologix 1400

VFDs Commissioned (Tuned/Parametrized): Schneider, ABB, Danfoss, Delta, Control Techniques

Network Components: RF Modems, Industrial Switches and Routers

📚 Key Learnings:

  • Power & control circuit testing
  • Transformer and lighting system commissioning
  • PLC programming (multi-brand)
  • VFD tuning and performance optimization
  • TCP/IP RF network design and configuration
  • Field equipment integration and safety interlocks
  • On-site logic modification and troubleshooting

🧰 Tools & Technologies Used: Schneider Unity Pro / EcoStruxure, Siemens TIA Portal & Step 7, RSLogix 500, Various VFD configuration tools, Industrial RF networking tools

💻 Languages Used: Ladder Logic, Function Block (for VFDs & relays), Structured Text (in some advanced logic cases), HMI Scripting (where applicable)