Coal Product Bins Electrical Upgrade

Customer: West Cliff Coal Preparation Plant, Illawarra Coal, NSW

Project type: Engineering and Construction

Project duration: 9 months

Control system: Allen Bradley Compact Guardlogix

Touchstone Systems was engaged to deliver the full electrical construction and engineering package for the upgrade of the West Cliff Coal Preparation Plant (WCCPP) product bins.

The scope included the complete decommissioning and replacement of the existing electrical control system. Works were delivered in a carefully staged approach, maintaining operation of two bins at all times while the remaining bin underwent structural refurbishment—ensuring continuity of plant operations throughout the project.

Key deliverables included:

• Construction and installation of three new PLC panels and motor distribution boards
• Implementation of a SIL2-compliant safety system
• Electrical engineering services, including development of single line diagrams, schematic drawings, and protection and coordination studies
• Commissioning and delivery of a detailed report outlining the optimal sequencing for bin decommissioning to support structural, electrical, and mechanical works

Delivered alongside major structural remediation, the project required close collaboration with structural and mechanical teams. Despite a constrained schedule, Touchstone Systems scaled labour resources to ensure the upgraded control system was commissioned on time and met all operational requirements.