When Nidec Drives Africa was approached to design a Variable Frequency Drive (VFD) Motor Management Centre (MCC) for the brand new “SL1A” Ship Loader at Dalrymple Bay Terminal in Mackay, Australia, the duty was clear – however removed from easy.
The purpose was to modernise offshore operations almost 4 kilometres out to sea, enhancing effectivity and embedding superior redundancy right into a system that had lengthy relied on outdated expertise.
A problem past the shoreline
The present infrastructure lacked the redundancy and security options required for contemporary industrial operations. Positioned offshore, the SL1A Ship Loader confronted distinctive challenges – chief amongst them, managing as much as 1 MW of regenerative vitality whereas linked to the 415Vac Australian electrical grid.
The system additionally wanted to robotically reconfigure its 1 MW regenerative Lively Entrance Finish (AFE) MCC energy circuits into an Lively DC-Bus configuration.
This might allow dynamic braking when the ship loader switched to its different diesel generator energy supply. And with the inherent dangers of such a high-power utility, each security circuit needed to meet the rigorous Security Integrity Stage 3 (SIL 3) requirements.
Designing the answer: Precision meets innovation
Over an intense 18-week design and construct interval, the Nidec crew engineered a sturdy, IP44-rated MCC constructed to “Type 4a” building requirements. The system options:
A centrally positioned incomer busbar part will accommodate the principle 3-phase, 415 Vac provide, together with a uncooked 3-phase, 415 Vac provide with impartial connection.
Devoted sections may also be offered for twenty-four Vdc and 48 Vdc small energy methods, together with overhead busbar chambers for 600 Vdc at 1800 Amps.
Six segregated MCC delivery sections, together with 2 x AFE models and a set of motoring VFDs.
The whole meeting measured 8600 mm x 800 mm x 2400 mm and weighed in at roughly 8.2 tonnes – together with exterior dynamic braking resistors.
To make sure ease of upkeep, every VFD energy unit was mounted on heavy-duty, withdrawable sliders. Operators can entry door-mounted controls and distant keypads for real-time diagnostics and operational knowledge per cubicle.
The system was powered by Management Strategies’ M702 VFDs, every outfitted with twin Secure Torque Off (STO) performance, guaranteeing full SIL 3 compliance. All communications had been streamlined through Ethernet /IP.
The payoff: security, effectivity, and scalability
The end result was a custom-engineered MCC that delivered on each entrance:
- Enhanced security: Twin STO options and SIL 3 compliance considerably lowered electrical hazards.
- Improved effectivity: Seamless reconfiguration between energy sources optimised vitality use and efficiency.
- Ease of upkeep: Withdrawable sliders and accessible controls minimised downtime.
- Scalability: The modular design allowed for future upgrades with minimal disruption.
A system constructed for complexity
The MCC supported a variety of functions, every vital to the ship loader’s operation:
- Twin Lively Entrance Finish (AFE1 and AFE2) VFDs (Multi-Grasp/Follower)
- Various Lively DC-Bus system when working through diesel generator energy supply
- Twin Growth Luff Winch (BLW1 and BLW2) VFDs (Multi-Grasp/Slave)
- Lengthy Journey VFDs (LT1, LT2, LT3)
- Growth Shuttle Winch (BSW) VFD
- Tele Chute Winch (TCW1 and TCW2) VFDs
- Hose and Cable Reel (CR and HR) VFDs
This venture stands as a testomony to what’s attainable when engineering precision meets real-world complexity. Nidec Drives Africa didn’t simply ship an answer – they redefined what’s attainable for offshore industrial automation.
