Projects

Mining

Power Electric Switchboards has successfully met the deadline for completion of a large contract for Xstrata’s Ernest Henry mine, despite an accelerated delivery timeframe.

The project involved the manufacture of two switch rooms, several motor control centres and Yokogawa DCS panels for the current expansion of the mine, which is located around 40 kilometers north of Cloncurry in north-west Queensland.

PES was awarded the contract by project managers Ausenco in May 2010 and completed delivery in early November – an impressive turnaround considering the scale of this project.

Credit for the successful completion of this project must go to Doug McElroy’s management and the hard work of workshop staff including Trevor Schodde, Steve Veneris and the team.

The team’s excellent work has led to Ausenco awarding PES a follow up contract for the supply of an additional switchroom and equipment for the mine’s Regrind Plant.

The Ernest Henry mine expansion includes the development of a magnetite extraction plant and an underground mine, which will extend the mine life until 2024.

Carborough Downs Coal Mine is currently undergoing an extensive expansion project which includes the introduction of a longwall mining system and expansion of the coal handling and preparation plant, and will increase the mine’s production of coking coal and PCI by up to four million tonnes a year.

The mine, which is predominantly owned by Brazilian resources company Vale and its joint venture partners, including Tata Steel, Nippon Steel and Posco, will become one of Australia's largest coal mines when the upgrade is completed in late 2009.

Power Electric Switchboards was awarded the contract to supply a motor control centre, switchroom and associated control panels for the expansion project, by project managers Ausenco. The switchroom was completed and delivered to Carborough Downs near Moranbah in June 2009.

The Rolleston Thermal Coal Project in the South West of the Bowen Basin in central Queensland was developed at a capital cost in excess of A$ 500 million. This includes the acquisition and construction of two draglines, one which was commissioned in October 2005. The second is scheduled to commence operation in the second quarter of 2007.

Power Electric Switchboards was awarded the contract for the manufacture of Motor Control Centres and distribution switchboards for the draglines as well as the Rolleston accommodation village Main switchboard and distribution switchboards.

The Motor Control Centres for the Rolleston Project were manufactured by Power Electric Switchboards in 2005 and 2006.

Ensham’s equipment optimisation program included the purchase of a new 6600 tonne Bucyrus 8750 dragline to cater for future expansion of operations and slash unit cost of production from the open cut operations. The $100 million contract with Bucyrus Australia was commenced in December 2004, with the dragline commissioned in Q4 2006.

  • • The Bucyrus 8750 is the world’s second largest dragline and will increase stripping capacity by approximately 60% while shaving 75% off overburden removal costs.
  • • A key feature of the Dragline 4 project was the high local content in the steel fabrication and cast components 85% of which were supplied and manufactured within Australia.
  • • Construction of the dragline involved steel manufacturing, heavy engineering, fabrication and casting components produced in Australia as well as in widespread centres in the USA.

The Motor Control Centres, Power Distribution Boards, and Control Cubicles were designed and manufactured to meet the requirements of the project by Power Electric Switchboards in Brisbane in collaboration with Bucyrus Australia Pty Ltd.

In October 2006 copper producer CopperCo Ltd signed an Engineering, Procurement, and Construction Management (EPCM) contract with Ausenco Ltd for the execution of the Lady Annie copper project 150km North West of Mt Isa in Queensland.

Ausenco awarded the contract to Power Electric Switchboards to design and manufacture the following Motor Control Centres:

  • • Process Area MCC and Switchroom
  • • Agglomeration and Acid Unloading MCC
  • • Primary and Booster Pump Station MCC’s

The Lady Annie copper oxide project was officially opened with the first copper cathode being shipped in October 2007. Production commenced at a rate of 19,000 tonnes a year and is expected to be ramped up to an ultimate production target of 30,000 tonnes a year. The mine, which has a resource of about 33 million tones is expected to have an initial mine life of eight to nine years.

The Phu Kham Copper-Gold Project in Laos is located approximately 100km North of the capital, Vientiane and contains a mineral resource of 1.2 million tonnes of copper and 1.5 million ounces of gold. The Project, which has an estimated development capital value of US$232 million, is the second phase of development of the Phu Kham deposit, and is targeting a 9 million tonne per annum flotation operation at Phu Kham, producing 50,000t of copper and 50,000oz of gold in concentrate annually. Commissioning of the project is anticipated to start in late 2007 ready for first concentrate production in mid-2008

Power Electric Switchboards was awarded the contract by Siemens (for Ausenco) for the design and manufacture of five 690V Motor Control Centres, UPS Panels, and Transportable Switchroom Buildings for the project.

In addition Power Electric Switchboards was awarded the contract for manufacture of the DCS Panels, including installation in the Switchrooms, for the project by Yokogawa Australia.

Power Electric Switchboards was awarded the contract to design and manufacture the following Motor Control Centres as part of the Universal Dig & Dump (UDD) upgrade project on Dragline 26 (Marion 8050) and Dragline 41 (Marion 8200) at BMA’s Blackwater mine:

Dragline 26

  • Power Control Room MCC
  • Essential Services MCC
  • Fan MCC

Dragline 41

  • Power Control Room MCC
  • Essential Services MCC
  • AC Distribution

Power Electric Switchboards designed and manufactured six motor control centres for three new Bucyrus 495HD Shovels at Boddington Gold Mine in Western Australia over a period of 4 months, with the MCC’s for the 3rd shovel being delivered in November 2007.

The design of the switchboards required unique customisation of our MCC design to meet Bucyrus requirements and accommodate the space constraints within the shovels.

Power Electric Switchboards has completed the supply of switchboards and motor control centres for the Bucyrus 8750/32 electric walking dragline for Anglo Coal’s Lake Lindsay mine in the Bowen Basin.

The $1 million contract included the supply of:

  • Two 415 volt main switchboards
  • Seven motor control centres
  • Ten distribution boards
  • Ten ancillary boards

The 5600 tonne dragline will be Australia’s first alternating current (AC) dragline and will benefit from improved power efficiency and fewer components resulting in less maintenance and downtime.

The dragline is being erected on site at Lake Lindsay mine and will be able to walk itself around the pit using two shoes more than 21 metres long and 4 metres wide. It will feature a boom over 109 metres long and will include more than 28 000 kW of installed motor power.

Lake Lindsay is an open-cut coal mine in the Bowen Basin which is operated and managed by Anglo Coal Australia. The mine adjoins Anglo Coal’s existing German Creek operations and was completed in 2008. Peak mining activities are expected to be reached in 2009, at which time Lake Lindsay’s saleable production will be around 4 Mtpa. It is estimated that the mine contains approximately102 Mt of saleable reserves.

For external pictures of the Lake Lindsay dragline, visit Bucyrus' website.

Wesfarmers’ Curragh mine is situated 200 kilometres west of Rockhampton and processes around seven million tones of metallurgical and steam coal annually.

Curragh’s export metallurgical coal is shipped to customers in Japan, South Korea, South-East Asia and Europe. Its steam coal is produced for domestic power generation and is transported directly to Stanwell Power Station and Gladstone Power Station by rail.

Power Electric Switchboards has completed extensive work on the dragline fleet at Wesfarmers’ Curragh. In October 2007, PES completed a full upgrade of Curragh Dragline 302. More recently in September 2008, PES completed the upgrade of Curragh Dragline 302 in September 2008.

Dragline 302, a Marion 8200 built in 1983, required a complete overhaul and was out of action for almost fifteen weeks. This is considerably longer than the standard eight week maintenance shutdown period. Power Electric Switchboard’s upgrade included the supply of a 415 volt main switchboards, two motor control centres, ancillary switchboards and a motion disable isolator cubicle.

Water

Power Electric Switchboards has won a significant contract to supply switchboards and motor control centres for the Nebo Road Water Treatment Plant in Mackay.

The job, which was awarded to PES by project manager Logicamms, includes the supply of:

  • The main switchboard;
  • Filter process motor control centre;
  • Dewatering motor control centre;
  • Chemical dosing motor control centre; and
  • Metering and distribution boards.

The project is on schedule and will be delivered in the New Year. Michael Kinne should be acknowledged for his excellent management of this project, which has involved nearly the entire workshop staff.

The Nebo Road project is one in series of Wastewater Treatment Plant projects that PES have undertaken around Queensland including Sandgate, Oxley Creek, Wacol Murrumba and Wynnum.

The Nebo Road Water Treatment Plant will be completed in 2011 and will provide treated water for Mackay’s population.

In December 2008, PES was contracted to manufacture five motor control centres for the Murrumba Downs Wastewater Treatment Plant upgrade project. PES were awarded the contract by Richard Flanagan and Company.

The purpose of the WWTP upgrade project is to increase the capacity of the facility to 30.8 megalitres per day to meet the demands of a growing population within Brisbane's Northern Growth Corridor and is an extension to the Advanced Water Treatment Plant already on site.

In December 2008, PES was contracted to manufacture five motor control centres for the Murrumba Downs Wastewater Treatment Plant upgrade project. PES were awarded the contract by Richard Flanagan and Company.

The purpose of the WWTP upgrade project is to increase the capacity of the facility to 30.8 megalitres per day to meet the demands of a growing population within Brisbane's Northern Growth Corridor and is an extension to the Advanced Water Treatment Plant already on site.

The Murrumba Downs Advanced Water Treatment Plant (AWTP) was officially opened on November 3, 2008. The $47 million plant became operational on September 15, two weeks ahead of schedule, after it was fast-tracked under the State Government’s Regional Drought Strategy.

The AWTP uses the latest technology in bio nutrient removal and odour control to provide around four million litres of recycled water per day for use in industrial applications such as the Visy Pulp and Paper Mill at Petrie. This is equivalent to the average daily water use of 28 000 people. By reducing this demand on drinking water supplies, the AWTP will help meet the needs of the growing population within Brisbane’s Northern Growth Corridor.

The project was completed by the Murrumba Alliance which comprised of Moreton Bay Regional Council (MBRC), the John Holland Group and environmental services firm MWH.

Power Electric Switchboards was awarded the contract to design, manufacture and supply motor control centres for the project by electrical contractor, Richard Flannagan and Company.

The project was worth nearly $1 million and was completed and delivered in April 2008.

The Brisbane Water Enviro Alliance (BWEA) was formed in December 2002 between Brisbane Water, JWP, John Holland, Aquatec Maxcon and MWH to design and implement the upgrades of the wastewater treatment plants at:

  • Wacol (completed at the end of 2005)
  • Sandgate (completed in mid 2006)
  • Oxley (completed in early 2007)
  • Wynnum (completed in late 2007)
    • The BWEA uses state of the art technology and processes to deliver upgrades that have the following benefits:

      • Improved treated wastewater quality reducing the impact on Brisbane’s waterways.
      • Significant reductions in Nitrogen and Phosphorous levels in treated wastewater with an estimated reduction of up to 600 tonnes per annum of nitrogen entering Moreton Bay
      • Reduction of odour within and surrounding the wastewater treatment plants
      • Ability to cater for increased population growth and required water treatment capacity, and large wet weather wastewater inflows
      • Replace outdated equipment with new state-of-the-art technology

      Power Electric Switchboards designed and manufactured the Motor Control Centres for the BWEA upgrade projects at all four of the abovementioned wastewater treatment plants.

      More detailed information and pictures on the Motor Control Centres for the Oxley and Wynnum WWTP’s and the Wynnum AWTP is given in the following links:

      • Oxley Waste Water Treatment Plant
      • Wynnum Waste Water Treatment Plant
      • Wynnum Advanced Water Treatment Plant

The Bundamba Advanced Water Treatment Plant (AWTP) is a component of the Western Corridor Recycled Water (WCRW) Project which will enable water from Brisbane and Ipswich’s treatment plants to be recycled for end users. Construction is split into two stages 1A and 1B, with the complete project scheduled for completion in 2008.

Located near Ipswich, the plant is aimed at alleviating pressure on South East Queensland’s existing dams and waterways by providing an alternate water supply for end users in the region, initially Swanbank power station. The plant will provide better than Class A+ recycled water and is unique in Australia due to the application of combined technologies involving micro-filtration membranes, reverse osmosis membranes and advanced oxidation using UV irradiation and peroxide.

Power Electric Switchboards was awarded the contract to design and manufacture the 18-pulse Variable Speed Drive Cabinets for Siemens for 4 x 400kW VSD’s and 4 x 560kW VSD’s for the Reverse Osmosis Pumps at the advanced water treatment plant.

Each of the VSD cabinets was designed with a control section and three separate rectifier tiers with common DC bus connection to a single motor inverter tier.

Construction of the BWEA upgrade to the Oxley Creek WWTP was completed in February 2007.

  • The upgrade has reduced the nitrogen content in the treated wastewater from 1170 kilograms per day to 112 kilograms per day, a reduction of 90%.
  • The Australia-first thermal hydrolysis system is now in operation and treats biosolids to a high standard, making them readily usable for soil and fertiliser applications.
  • Methane gas produced during the treatment process assists in producing energy for the plant, reducing the need to source energy from external power suppliers.
  • A water tanker collection area has been established at the plant to provide the treated wastewater for use in construction activities, including dust suppression.

Power Electric Switchboards was awarded the contract to design and manufacture the Motor Control Centres for the BWEA upgrade project at Oxley WWTP, as follows:

  • Bioreactor 05 & 06 MCC
  • Blower Switchboard
  • Final Area MCC
  • Final Settling Tank MCC’s 09 to 13
  • RAS MCC
  • Sludge Handling MCC
  • WAS Dewatering MCC
  • Odour Control MCC

The Wynnum WWTP was upgraded in a similar fashion to the Sandgate WWTP with construction commencing in June 2006 and completed in the 3rd Quarter of 2007.

A new plant with inlet works, bioreactor, final settling tanks and UV disinfection, was constructed on the site next to the existing plant and has replaced the existing trickling filter plant.

The upgrade includes:

  • A new biological nutrient removal system to treat up to 9 million litres of wastewater a day, removing 80% more nitrogen than the previous treatment system
  • Environmentally friendly UV disinfection, replacing the previous chlorine dosing method, eliminating chemicals in the discharged treated wastewater
  • The capacity of the plant has also been increased by around 6%.
  • Power Electric Switchboards has completed design and manufacture of the Motor Control Centres for the BWEA upgrade project at Wynnum WWTP, including:

  • Bioreactor 1 & Blower MCC
  • Inlet Sludge MCC
  • 2 x Final Settling Tank (FST) 316 Grade Stainless Steel MCC’s with sunshields

Caltex’s Lytton oil refinery will be the first major industrial operation in Queensland to commence large-scale use of recycled water, thanks to an $11.78 million State Government incentive funding package for Brisbane City Council to upgrade its Wynnum Wastewater Plant so that treated recycled water can be piped to the Caltex refinery, enabling Caltex to reduce consumption of Wivenhoe Dam water at the refinery by 4.5 Megalitres a day by replacing it with recycled water from the Wynnum plant.

Caltex is Brisbane’s second-largest user of water and will use the recycled Class A+ water in the petroleum refinery’s cooling towers and boilers helping to conserve drinking water supplies in South East Queensland as well as reducing the amount of treated wastewater discharged into Moreton Bay.

The supply of Class A+ water to Caltex required the construction of a microfiltration and reverse osmosis plant for which the Brisbane City Council has contracted the Brisbane Water Enviro Alliance (BWEA).

Power Electric Switchboards has designed and manufactured the MFRO Plant Motor Control Centres for this AWTP project which is scheduled to be completed in the 1st Quarter of 2008.

Other

In July 2010, Power Electric Switchboards successfully completed a large supply contract for the iSeek Data Centre at the Brisbane Airport Corporation.

The extensive job included the supply of three main switchboards (4,000 amps, 100kA), several mechanical services switchboards, two UPS boards (1,000 amps) and several distribution boards. PES also supplied three 800 amp PDU boards, which were powder coated black to suit site requirements. All switchboards were ABB ArTu modular switchboards and were fitted out with ABB switchgear.

The $30 Million iSeek facility is a high density, purpose built data centre that will build on the success of iSeek's Woolloongabba facility. The data centre claims to have achieved a 1.3 PUE rating by the Green Grid, reportedly one of the lowest for any data centre in Australia.

Focus magazine reported that:

"The center has used a range of building innovations, from thermal insulation to non-penetrable roofing to help it achieve its standards, while maintaining high security levels. Throughout the entire structure, according to iSeek, energy efficiency has been taken into according. It feature hot/cold aisle configurations as well as a building management system to monitor and administer electrical and mechanical systems in the building itself and uses free cooling from BMS. It also collects 97% of its roof water and 10% of its air conditioning condensate, which is then put back into the Brisbane Airport Corporation's reservoir system."

In mid 2006 Power Electric Switchboards was awarded a contract by the Central Queensland Ports Authority as part of the Auckland Point Terminal Electrical Infrastructure Upgrade at Gladstone Port, upgrading switchboards for the bulk loading/unloading facilities for Magnesite and Calcite.

Power Electric Switchboards completed the design and manufacture of a Motor Control Centre, Metering Switchboard, and Transportable Switchroom Building for Central Queensland Ports Authority (CQPA) as part of the Auckland Point Terminal Electrical Infrastructure Upgrade at Gladstone Port.

Power Electric Switchboards completed the design and manufacture of a Main Power Distribution Switchboard and Generator Switchboard, together with 14 Sub Distribution Boards and 128 Tenancy Distribution Boards to cater for the electrical services in the new section of the Westfield Chermside Shopping Centre completed in mid 2006.

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