Balranald Plant Process Control System

Solution: Pivotal implemented a structured, standards-driven PCS delivery model aligned with modern ASM-styled SCADA. The process employed by Iluka to operate the plant was relatively complex with a novel method of underground mining. Pivotal developed the standards for the entire site and then developed detailed functional specifications for each area and used this as the single source of truth for programming, FAT, and SAT.

The details from the functional specifications were then entered into a “PCS Database” that had rules for checking data validity and conformance to standards, design and process. Our in-house auto-generation utility was then used to connect to the database and generate the logic for 90% of the PLCs in scope of the project as well as elements of the SCADA project.

Comprehensive off-site testing was undertaken, including switchroom and MCC FATs, mobile mining plant integrated testing, and remote I/O panel testing. Each FAT was supported by formal test documentation and defect tracking. Close collaboration with Iluka, the EPCM, and key vendors was maintained through regular progress reporting, earned value tracking, staged design reviews, and design reviews to ensure operational readiness.

Comprehensive and thorough off-site software FAT (by a separate team of software testers) minimised on-site defects and supported a predictable commissioning phase, positioning the Balranald Project to achieve first ore in line with the Clients schedule and budget.

Platforms Used: Schneider Electric M580 ControlExpert, Aveva Plant SCADA 2023 R2, OPC UA