Perth Transport Authority Projects

Working in conjunction with Schneider Electric, supplying ongoing upgrades to the existing infrastructure, SG Controls assisted in ensuring the continuation of services across several SCADA platforms. These upgrades included PLC and SCADA redesign, Software and Hardware upgrades and electrical install and refurbishment.


SG Controls’ scope for this project included:

  • Claremont Carpark Lighting Control
    • Supply of PLC and Remote IO panels
    • Site installs of panels
    • Electrical install including termination of field cables onto Krone distribution frame
    • Commissioning assistance


  • Joondalup PLC Upgrade (Stirling, Whitfords, Warwick, Leederville)
    • Supply of site PLC panels
    • Install of PLC panel and HMI enclosure
    • Electrical Installation
    • Commissioning assistance

Bengalla Coal Mine QMS

SG Controls have been engaged to deliver a complete Quality Management System (QMS) and product tracking system to the Bengalla Coal Mine and Processing Site.

Integrating 3D stockpile model including Stacking and Reclaiming using Real-time volumetric inventory to predict outload quality based on simulated reclaim operations for 3 Stackers, 3 Reclaimers, and 3 Stockyard Rows for the Coal Processing Plant.

The QMS is capable of reporting the aggregated quality of a stockpile, grouped in terms of the source trains, the product types, or the time when the product was stacked onto the stockpile.

This way the customer can make intelligent decisions when reclaiming and loading trains to provide their clients with the product that they desire.

Mobile Machine Upgrades

SG Controls have been awarded multiple contracts to undertake mobile machine upgrades at RTIO, BHP and FMG Mine sites in the Pilbara, WA. The various project scopes comprised predominantly of stackers, reclaimers, and other mobile machinery, and included the design, engineering, construction, reconfiguration, validation, FAT, SAT and commissioning of PLC, SCADA, ACS and SMS systems.

The contracts included, but were not limited to:

  • Controls design and engineering
  • Hardware and Software selection
  • Development of PLC and SCADA Software
  • RIO cubicle design and engineering
  • Re-configure and validate ACS / SMS systems
  • FAT, SAT and Commissioning
  • Supply of all reports, diagrams, drawings and documents

WWTP 4G Communication Telemetry Upgrades

SG Controls were awarded multiple contracts to undertake 4G Communication telemetry upgrades at various Waste Water Treatment Plants across Western Australia.

The contracts include:

  • Communication telemetry panel design, construction, installation and commissioning
  • Telemetry upgrades, including removal of existing power supplies
  • Regular site inspections and ongoing maintenance
  • Design documentation

Port of Newcastle Ship-unloader Project

Tenova Australia have awarded SG Controls the design, manufacture and supply contract for the Port of Newcastle ship-unloader electrical, instrumentation and control system design.

The contract’s scheduled completion is December 2019, and includes:

  • Turnkey project of electrical, instrumentation and control system design, procurement, manufacture and supply of a 1,200 tph free digging capacity jib type grab ship-unloader capable of handling multiple product types
  • Onboard PLC includes integrated sway control system
  • Overseas construction, verification and commissioning
  • Final commissioning in NSW
  • Design, Selection and Procurement of all items associated with electrical, instrument and control equipment scope, including:
    • Upper and lower switchrooms
    • LV MCC’s
    • Variable speed drives
    • HV transformer
    • Cabling and cable support
    • Field instrumentation, control stations and marshalling panels
    • Operator cabin

Tasiast Mine 12K Expansion

SG Controls were awarded the design, programming, integration, testing and commissioning of the 12K expansion project for the Tasiast mine site’s process plant including a new process train and three power stations’ control systems.

As a result of our skilled, reliable and quality workmanship our scope was expanded to cover a rewrite of the control system for existing equipment, and its integration.

The integration covered major upgrades to the process control network, with over 30 Ruggedcomm network switches used in the dual ring topology and linking 14 M580 PLCs with Wonderware System Platform SCADA, plus multiple small satellite vendor systems.

We are currently completing upgrades to the power station as part of the ongoing expansions, with control system and network development underway and commissioning expected in November this year.

The ongoing scope includes, but is not limited to:

  • Electrical, Instrumentation and Controls design drawings, documents and calculations
  • Controls development of Process Plant and Power Stations
  • Hardware and control system design, supply and install
  • PLC, SCADA and Historian development, supply and commission
  • New network architecture design, supply and commission including the supply of all cubicles
  • Network upgrade and design changes for all brownfields network equipment
  • Instrumentation, Smart relays and VSD configuration including commissioning
  • Design and integration of over 52 vendor packages
  • Start-up and commissioning
  • Power integration manager and full on-site project delivery and operations support

Jaguar Copper/Nickel

Since completing the control systems design, development and commissioning for the Jaguar Copper Nickel Processing Plant in 2007, SG Controls have provided extensive site support and upgrades. Services include:

  • Shutdown support
  • System repair and maintenance
  • All control system upgrades and fault finding

Mundaring Water Treatment Plant

SG Controls are providing full E&I operations and maintenance services to the Water Corporation’s Mundaring Water Treatment Plant, situated an hour North East of Perth.

Working with Acciona Trility Joint Venture (ATJV) SG Controls involvement covers:

  • LV, HV and HVAC Electrical maintenance
  • Instrumentation
  • 24/7 On-Call support
  • Drafting services
  • Projects and upgrade work

East Intercourse Island Stackers Replacement

The East Intercourse Island Stackers Replacement Project comprises of the construction of three new stackers  and seven new trippers to replace the existing machines.

The stackers are rail mounted luffing, slewing and long travelling machines designed to stack iron ore onto a stockpile over the entire longitudinal travel length.

The project utilises multiple safety systems to ensure the functional safety of the site, and is fully complaint to all AS4024.1503 Australian safety standards.

The site is located on East Intercourse Island, Dampier WA. The replacement machines are capable of sustaining a 25DMTPA rate.

SG Controls’ scope for this project includes:

  • Engineering Services
  • Electrical and Instrumentation design
  • Commissioning management for Mechanical, Electrical, Instrumentation and Process Control Systems


Parker Point QMS & 3D Modelling

SG Controls have been engaged to deliver a complete Quality Management System (QMS) and product tracking system, integrating 3D stockpile modelling.

The works include Stacking and Reclaiming using Real-time volumetric inventory to predict outload quality based on simulated reclaim operations for 4 stackers, 3 Reclaimers, 6 Stockyard Rows and one bulking row, with allowance for 8 stockpile per row for the existing Parker Point Iron Ore Shipping facility here in WA.

The project scope includes:

  • Quality Management System design and implementation
  • 3D modelling development and integration
  • Product tracking system design, development and implementation