SG Controls mobilised a team of electricians and electrical engineers to supervise, install and commission the electrical systems and instrumentation of the new stacker at the Karara Iron Ore stockyard. Our involvement began following a handover from the mechanical construction team and continued until the machine was signed off for autonomous operations.


  • Electrical installation and control system commissioning of FLSmidth’s tailings stacking machine at Karara Iron Ore Project
  • $65M project to supply a machine capable of stacking process plant dry tailings over 4 square kilometres with an operational life of fifteen years
  • The Tailings Stacking Facility (TSF) consists of multiple, independent, coordinated machines that are designed and programmed to function as a complete unit. In general, each machine is supplied with its own dedicated Programmable Logic Controller (PLC) that is configured and programmed to carry out all functionality and safety for that machine. These individual PLC’s are networked together using a combination of copper, fibre optic and wireless Ethernet networks to form a unified system.
  • Site sits to the south of the main Karara Iron Ore processing plant


  • Designed to operate at a rate of 2500 TPH  twenty four hours per day in line with staking tailings from the 8mtpa process plant

Products Handled

  • Process plant tailings: dried tailings with a 15% moisture level and particle size of under 4mm

Scope of upgrade

  • Electrical installation and rectification of existing equipment
  • Electrical and control system commissioning of facility

Our involvement

Electrical supervision, installation and commissioning of:

  • Installation and commissioning of process control cubicles
  • HV & LV reticulation and connection to existing services
  • HV SEL protection relay installation and commissioning
  • Commissioning of conveying and stacking machines
  • PLC to PLC communication set up and commissioning
  • Smart relay, motor starters and VSD programming and commissioning
  • GPS module programming and integration
  • Electrical and software commissioning management services
  • Quality assurance inclusive of all testing, CVC and verifications
  • Interfaces to existing plant & equipment