24 Vdc and 48 Vdc small power systems, along with overhead busbar chambers for 600 Vdc at 1800 Amps. • Six segregated MCC shipping sections, including 2 x AFE units and a suite of motoring VFDs. The entire assembly measured 8600mm x 800mm x 2400mm and weighed in at approximately 8.2 tonnes, including the external dynamic braking resistors. Each VFD power unit was mounted on heavy-duty, withdrawable sliders, for ease of maintenance; and operators can access door-mounted controls and remote keypads for real-time diagnostics and operational data per cubicle. The system was powered by Control Techniques’ M702 VFDs, each equipped with dual Safe Torque Off (STO) functionality, ensuring full SIL 3 compliance. All communications were streamlined via Ethernet /IP.
The custom-engineered MCC delivered: • Enhanced Safety: Dual STO features and SIL 3 compliance significantly reduced electrical hazards.
• The task: To design a Variable Frequency Drive (VFD) Motor Control Centre (MCC) for the new ‘SL1A’ Ship Loader at Dalrymple Bay Terminal in Mackay, Australia. • The goal: To modernise offshore operations nearly 4km out to sea, enhancing efficiency and embedding advanced redundancy into a system that had long relied on outdated technology. This, however, was far from simple. The
existing infrastructure lacked the redundancy and safety features required for modern industrial operations. Positioned offshore, the SL1A Ship Loader faced challenges, including managing up to 1MW of regenerative energy while connected to the 415Vac Australian electrical grid. The system also needed to automatically reconfigure its 1 MW regenerative Active Front
End (AFE) MCC power circuits into an Active DC-Bus configuration. This would enable dynamic braking when the ship loader switched to its alternative diesel generator power source. Every safety circuit also had to meet the rigorous Safety Integrity Level 3 (SIL 3) standards.
Over an intense 18-week design and build period, the Nidec team engineered a robust IP44-rated MCC built to ‘Form 4a’ construction standards. The system features: • A centrally located incomer busbar section that will accommodate the main 3-phase, 415 Vac supply, including a raw 3-phase, 415 Vac supply with neutral connection. • Dedicated sections will also be provided for
• Improved Efficiency: Seamless reconfiguration between power sources optimised energy use and performance.
• Ease of Maintenance: Withdrawable sliders and accessible controls minimised downtime.
• Scalability: The modular design allowed for future upgrades with minimal disruption.
The MCC supported a wide range of applications, each critical to the ship loader’s operation: • Dual Active Front End (AFE1 and AFE2) VFDs (Multi-Master/Follower)
• Alternative Active DC-Bus system when operating via diesel generator power source • Dual Boom Luff Winch (BLW1 and BLW2) VFDs (Multi-Master/Slave) • Long Travel VFDs (LT1, LT2, LT3) • Boom Shuttle Winch (BSW) VFD • Tele Chute Winch (TCW1 and TCW2) VFDs • Hose and Cable Reel (CR and HR) VFDs. This project stands as a testament to what’s
possible when engineering precision meets real-world complexity, the company concludes.
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