The project involved replacing legacy motor control and communication systems with Siemens SIMOCODE motor management units integrated via a PROFINET communication network. Verbrec’s scope focused on delivering a constructible, shutdown-ready design for the upgraded motor control centre, including MCC layout modifications, PLC configuration and network topology. The objective was to modernise the system while minimising operational disruption and supporting efficient execution during planned shutdown periods.
Cloudbreak
Pilbara mining operations upgrade location
2024–2026
Project delivery timeframe
PROFINET
Modern communication protocol replacing legacy DeviceNet
Verbrec implemented a strategy that enabled significant preparatory work to be completed prior to shutdown by pre-installing selected components within cable spaces external to the MCC tiers. This reduced the volume of work required during critical shutdown windows and supported faster execution. The design also enabled a streamlined transition from DeviceNet to PROFINET, allowing the upgraded system to be brought back online efficiently with minimal disruption to ongoing operations.
Verbrec delivered detailed electrical and control system design for the switchgear upgrade, including the integration of Siemens SIMOCODE components within MCC cable zones and the configuration of the associated PROFINET network. The design incorporated a detailed construction methodology and procurement-ready documentation to support efficient execution. Particular focus was placed on enabling a controlled cutover process, ensuring both legacy and new communication systems could be managed during transition and commissioning.
The delivered design enabled Fortescue to significantly reduce shutdown duration by completing a large portion of installation and preparatory works ahead of planned outages. This approach improved execution efficiency and reduced risk during critical shutdown periods. The design also supported controlled commissioning by allowing DeviceNet and PROFINET systems to be managed concurrently during cutover, helping minimise the impact of issues and ensuring a smoother transition to the upgraded system.