SG Controls were engaged to provide electrical and controls systems engineering services for the Tutupan OPCC Mining upgrade. An overburden stacking facility was installed and commissioned, with control systems integrated into the existing mine site PLC logic. The project was completed on time and budget with the new stacking facility successfully removing the overload from existing equipment and improving mine efficiency.


  • The OPCC project is an overburden handling system designed to receive overburden from PT Adaro’s haul truck fleet at the rim of the pit, then size, convey, and stack overburden at a rate of 12,000 TPH
  • Equipment control functions are performed with Allen Bradley PLCs
  • Programmable Logic Controllers (PLC) with an ‘intelligent’ pull cord system used in conjunction with conveyor instrumentation along the length of the conveyor
  • Conveyor drive motor starting and acceleration control for the Surge Feed Conveyor is provided by integral PLC controllers located in the respective SRC contactor cabinets


  • Designed to operate at a rate of 12,000 TPH

Products Handled

  • PT Adaro mining operations overburden material

Scope of works

  • Electrical and control system commissioning of facility

Our involvement

Electrical supervision, installation and commissioning of:

  • Commissioning of process control cubicles
  • HV & LV reticulation and connection to existing services
  • HV SEL protection relay installation and commissioning
  • Series of conveyors, crushing circuits and sizing circuits
  • 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