RPEQ Certification for a Hazardous Area Industrial Control System Upgrade in Brisbane
A major industrial facility in Queensland required an upgrade of its aging control and automation systems to improve reliability, safety, and compliance.
The project involved PLC systems, control panels, hazardous area equipment, and field instrumentation upgrades.
Project Background
The facility engaged our RPEQ-certified engineers to perform an independent design review and certification of the proposed electrical and automation system upgrades.
Engineering Challenges
- Legacy PLC integration with modern systems
- Outdated electrical documentation
- Hazardous area compliance requirements
- Control panel redesign and segregation
- Minimising production downtime
Our Engineering Approach
A structured engineering review was conducted covering design verification, compliance assessment, and risk evaluation.
Design Verification
Electrical drawings, single line diagrams, control philosophies, and panel layouts were reviewed against site conditions.
Compliance Assessment
- AS/NZS 3000 Electrical Wiring Rules
- AS/NZS 60079 Explosive Atmospheres
- AS/NZS 61439 Switchgear Standards
- WHS regulations compliance
PLC and Control System Review
The PLC architecture, I/O allocation, safety functions, communication systems, and redundancy were evaluated for reliability and scalability.
Risk Assessment
Potential safety and operational risks were identified and mitigation strategies were recommended before construction.
Key Recommendations
- Update hazardous area documentation
- Improve control and power segregation
- Enhance earthing and surge protection
- Optimise PLC I/O allocation
- Standardise labelling and documentation
Results and Benefits
- Improved compliance with Australian Standards
- Reduced engineering and construction risk
- Improved system reliability
- Better maintainability and scalability
- Faster commissioning process
Conclusion
This project highlights the importance of early involvement of RPEQ-certified engineers to ensure compliance, reduce risk, and improve project outcomes.
Independent engineering review significantly enhances safety, reliability, and long-term performance of industrial control systems.
Contact Us
Email: enquiries@iengaust.com.au
Phone: +61 2 8318 1490
