Client

CBH

Location

Geraldton, Western Australia

Industry

Agriculture

Overview

CBH is Australia’s largest grain co-operative, operating an extensive grain storage and transportation network of over 100 receival sites across WA. The CBH Narngulu site, located near Geraldton, consists of four open bulkheads and an additional six temporary bulkheads, contributing to a total grain storage capacity of 360,000 tonnes.

The client identified the need to construct two new Conveyor Loading Systems (CLS) to assist with the handling and in-loading of grain at the site.

Scope

Intellect Systems was engaged to undertake the design of the CLS electrical, instrumentation and control systems as well as the manufacture of MCCs and Remote HMI units for the Narngulu site.

The scope included:

  • Electrical, functional safety and control systems design
  • Supply and configuration of PLCs and HMIs
  • Modular object-oriented PLC and HMI development
  • Software development and training
  • Manufacture and supply of 2 MCCs
  • Manufacture and supply of 2 Remote HMIs
  • 2 x Static VAR compensation panels
  • De-Tarping Control Panels
  • Full system commissioning on site

Smarter Solutions

To support the expanding operations at Narngulu, the client required Intellect Systems to provide a complete and scalable solution that could be easily operated by seasonal personnel, aligned with CBH’s internal standards, and replicated to other sites.

The client’s standard designs allowed for a maximum conveyor length of 350m, whereas the new CLS systems were up to 530m in length. Intellect Systems was required to further develop the client’s standard to accommodate the larger cables, motors, and ancillary modifications necessary for the extended maximum length.

A risk assessment review and gap analysis were conducted to evaluate the impact of conveyor lengthening on functional safety, and a revised functional safety design was presented to the client.

Intellect Systems was also entrusted to undertake the manufacture and supply of two MCCs and two remote HMIs for the site. A simple and intuitive HMI interface solution was critical for ease of use by CBH’s seasonal workforce, so a Proface HMI installed in its own field enclosure provided straightforward control of the in-loading process. The system is remotely accessible for easy operation, monitoring, intervention and support.

The Narngulu wheatbelt location demanded robust products and high-reliability electrical design. The final solution included a static VAR generator to ensure the power supply was free from fluctuation, improving the stability of the electrical system while also increasing efficiency and reducing running costs.

The successful delivery of this project enhanced grain handling capacity at Narngulu whilst maintaining operational simplicity for seasonal staff. By combining Intellect Systems’ comprehensive engineering expertise with in-house manufacturing capabilities, CBH received a scalable and repeatable, fully integrated solution.