Commissioning and Maintenance of Electrical Systems in Greenfield Iron Ore Storage Yard

📍 Project Overview: This project was executed as part of the commissioning and operation of a greenfield iron ore storage and transport yard. It involved an integrated network of conveyors, stackers, reclaimers, transfer cars, and supporting electrical infrastructure ranging from 11kV HT panels to HMI control systems.

👷 My Role & Responsibilities:

• Testing and commissioning of electrical panels: 415V MCCs, 6.6kV HVMCCs, and 11kV/415V transformers, and Power and control circuits for conveyors, compressors, and yard machines.
• Design and development of PLC logic for field operations.
• HMI screen design and commissioning for real-time operator control.
• VFD tuning and parameterization for various machines.
• Design and modification of the RF system to centralize control via a single engineering point.
• On-site maintenance of all deployed systems, including PLC hardware and communication networks.

⚙️ Equipment & Technologies Involved:

• Material Handling Machines: Twin Boom Stacker (TBS), Wheel on Boom Reclaimer (WBR), Blender Reclaimer (BRC), Transfer Car
• Electrical Infrastructure: 415V MCCs, 6.6kV HVMCCs, 11kV/6.6kV/415V Transformers, Lighting Distribution System
• Automation Hardware & Software: GE RX3i PLC with Proficy Machine Edition, Genius Bus, OFC Network, GE Cimplicity HMI, ABB CRU380 PLC, ABB VFDs, GE Multilin Motor Protection Relays, Esteem RF Modems, Industrial Switches & Routers

📚 Key Learnings:

• Electrical commissioning of MCCs and HT panels in an industrial yard.
• Designing PLC logic and troubleshooting field issues in GE RX3i and ABB PLCs.
• Tuning and optimizing ABB VFDs for real-world mechanical loads.
• Deploying and modifying an RF-based engineering communication network.
• Integrating HMI control with real-time data using Cimplicity HMI.
• Long-term system maintenance and reliability practices for large-scale automation.

🧰 Tools & Platforms Used: GE Proficy Machine Edition, ABB Drive Tools, GE Cimplicity HMI, Multilin Relay Configurator, MS Excel, Pro Tools for diagnostics

💻 Programming & Configuration Languages: Ladder Logic, Function Block, Structured Text, HMI Scripting (GE Cimplicity)