• Aussie Rock Quarry

    Pro-Built Control was contracted to complete electrification works and control system engineering for a new crushing and screening fixed plant.

    The MCC panels were designed and constructed in our factory using state of the art control hardware from Rockwell Automation. The project utilized a Compact Logix 5380 PLC, E300 DOL starters, SMC Flex Soft Starters, and Powerflex VSD's  all communicating on EthernetIP via a Stratix 5700 managed switch.

    Pro-Built Control was able to offer a full operator control solution via the PlantPax Libraries with remote access via 4G and local Prosoft wireless network with multiple access points for mobile control of the plant via a tablet.

    Onsite field and MCC installation works were completed within 14 days, including cable trays, support systems, and motor cabling.

  • Paper Mill MCC Switchboard

    Our customer in the paper industry requested an MCC switchboard upgrade to replace aged existing boards. During the quoting process a fire damaged the existing boards. The project was expedited to provide new CUBIC switchboards to site.

    These dual sided switchboards utilize the CUBIC modular system, with ABB ACB's supplying individual feeders containing Allen Bradley E300 electronic overload relays, local operator stations, contactors, and Terasaki circuit breakers.

    With the assistance of our suppliers NHP and Remtron, and our electricians split over two shifts per day, and Flexilift forklifts to assist in loading the boards onto the truck, PBC delivered these panels in almost half the original project timeline to get the papermill back up and running.

  • Quarry Control System

    PBC was selected to offer a full turn key electrical solution for a new Primary and Secondary plant.
    The mechanical design and equipment selection was through the principle contractor QME P/L located in Bendigo, Victoria.
    The scope of works included;

    • Functional description
    • Technical safety specification
    • Design of Power distribution and MCC including light and power
    • Design of Electrical control system and instrumentation utilizing Rockwell Automation components.
    • Complete software and industrial IT design leveraging Allen Bradley PlantPAX libraries, Prosoft 4G remote access, programming and commissioning.
    • Manufacture and installation of all electrical systems and field wiring.
    • Factory acceptance testing
    • On site installation and commissioning.
    • Ongoing remote site support.
  • Paper Mill Siemens S5 to DCS Upgrade

    Paper Machine S5 upgrade to ABB 800xADCS

    The Siemens S5 Processor and IO were converted to Phoenix Contact Axioline Profi-Net IO XC modules communicating with the existing ABB 800xA DCS.All siemens S5 IO relocated to new IO panels, with all outputs individually fused to meet site specifications.

    One existing ABB controller (PM861) converted to PM891 to house the new application. Modifications to Profi-Bus & Profi-Net Networks through out the plant were required to accomodate the upgrade and minimise the changeover and commissioning downtime.

    In conjunction with the Siemens S5 Upgrade, the ABB DCS System was also upgraded from V4.X to 5.2. This requires a site wide upgrade of new servers and operator stations.

  • Waste Water Permanent Plume Mitigation System Switchboard

    Permanent Plume Mitigation System Switchboard

    Approx. 400 IO Switchboard and Control Panel containing the following;

    • Allen Bradley Compact Logic PLC
    • Digital IO, High Speed Counter Inputs, Remote Racks
    • ABB Automatic Transfer Switch for 3 phase supply & Generator Backup
    • Phoenix Contact Electronic circuit breakers
    • UPS
  • Paper Mill DAF Electrification & Instrumentation

    Electrification of new W625 MCC and equipment including;

    • MCC Switchboard with 400mm XLPE Feed
    • 11 off 415 VAC motors raging from 1.5 to 50kW
    • 5 off Dosing Pumps and controls
    • Various IP56 Series Outlets and Lighting.

    Instrumentation to suit the new control system including;

    • 550kPa Manifold and Valve Panel to drive knife gate valves
    • Flow Transmitter Panel Skid to feed 4 Flow Transmitters
    • 2 off Pressure Transmitters
    • 5 off Level Transmitters
    • 2 off Turbidity Skids

    Installation was carried out over a two month period in conjunction with mechanical assembly of the equipment generating unique challenges on a daily basis.

  • Sawmill MCC Replacement

    Our customers brief called for replacement of an ageing MCC and supply cabling used to power 'debarking' machinery in their timber mill.

    New electrical control panels required to upgrade the existing MCC were built at Pro-Built Controls premises prior to transporting to site.

    The project works included;

    • Complete all trenching work to accommodate the new supply including trench depth of 1500mm covered with "Quarter minus" screening compacted and covered with and additional 150mm of reinforced concrete and backfilled with remaining earth.
    • Supply and install new 150mm underground conduit (80mtr).
    • Supply and install new 100mm conduit for future cabling (40m).
    • Supply and install new 185mm 4C & E orange circ cable or equivalent.
    • Supply and install new 630 Amp MCCB bucket for the MCC 10.
    • Terminate test and energize the new supply.
    • Manufacture 4 bay distribution centre to replace the existing MCC & feeds to 16 plant items.
    • Remove existing MCC at planned shutdown (2 -3 Days)
    • Test and wire new distribution system prior to delivery
    • Supply and install 6 fortress key locks to existing guarding in the field.
    • Supply and install new fortress master key and key release system.
    • Incorporate one lockable 630 amp Circuit Breaker for single point of isolation.
    • Test and commission.
    • Create CAD electrical schematics and as built drawings

    Installation on the eve of Xmas shutdown, commissioning commencing Boxing Day.

    Overload & Contactors

  • Paper Machine DCS Upgrade

    Project requirements - project management, design, install and connect a DCS system to replace dated Siemens S5 and Taylor MOD systems to ABB AC800xA hardware.
    The installation was designed in parallel with the existing legacy system enabling full FATs and minimal disruption to production schedules.
    All new multicore cables were installed from the final point of field connection to MCC Marshalling panels where the IO was connected to multiple controllers depending on the machine process, prior to change over all new connections were tested from the final point of connection back to the respective controller verifying correct operation of each I/O.
    Installation included a new communications network linking all controllers via local Profi-Bus connections through converters to fibre and remote connections, additional server racks were also installed and connected to the DCS network via CAT5 cable.
    Testing included analog I/O and application of a process meter to ensure correct scaling.

    Duration: 12 Months
    Change over period: 72 hours
    Staff: 20
    I/O Count: 8000

  • Extruder Upgrade & Relocation

    Project requirements - decommission, relocate and upgrade cable extruder line and assist with commissioning during an MSD (Xmas period).
    Works included build/install new control cabinets comprising Schneider switchgear, Magelis HMI's and Advantys PLC with Modicon I/O.

    Duration: 10 weeks
    Staff: 6 

  • Evaporation Upgrade

    Installation of VSD's, general light & power, manufacture/installation of pneumatics distribution system and supplies for three new effectors and their associated control systems

    Duration: 3 months
    Staff: 6
    IO: 150


  • CO2 Detection & Control System

    Project requirements - design, manufacture, program, install & commission a CO2 gas detection, fan & louvre control system for an enclosed winery fermentation area.

    Duration: 5 months
    Staff: 6
    I/O Count: 150

  • Tri-Gen Integration

    Project requirements - integration of a new 400kW Packaged Co-Generation Plant to the mains supply via a 'BUS TIE' in the facilities main switchboard.

    Installation included VSD units.

    Duration: 3 Months
    Staff: 5

  • Bakery Roll Line Control System Upgrade

    This project presented a number of unique challenges for our engineering team including a 48 hour changeover window, missing data & CAD files and insufficient scope documentation. Our engineering staff recreated scope documentation as a forerunner to building, installing and integrating a new control system to suit operational requirements. Integration of the new control system necessitated reverse engineering existing control and equipment function, hardware consisted of approximately 300 I/O utilising an Allen Bradley Compact Logix system coupled with a PV+1500 colour touch screen. System design and layout required conforming to our customers current standards whilst ensuring all applicable industry and regulatory requirements were maintained.

    Duration: 12 weeks
    Staff: 11
    I/O: approx. 300

  • Fire Damaged Electrical Cable Restoration

    Fire had caused significant damage to electrical control & power cabling located in underground conduit & ducts.
    Pro-Built Control attended an emergency call out to bypass damaged wiring and install temporary power & control. Project restoration works necessitated reverse engineering system operation requirements and associated process control elements.
    All field, control and power wiring was traced from point to point to develop working schematics prior to rebuilding/rerouting cable runs.

    Duration: 2 days (until startup)
    I/O: n/a

  • 10MW Co-Gen Installation - Tumut NSW

    Project requirements - general electrification light & power with all associated cable ladder and tray
    integration  with Woodward Synchronisation Control and Bently Nevada vibration monitoring system.

    Duration: 3 months
    Resources: 20 staff including boilermakers/fabricators, electricians, engineering and project management staff
    I/O count: approx. 200

  • Paper Mill 3MW Co-Gen Installation - Coolaroo Victoria

    Project requirements -  electrification installation & commissioning of a newly installed steam turbine generation unit and its associated equipment comprising boiler, fuel handling, feed pump, MCC Room, turbine & generator controls.

    Works included - Integration with Woodward synchronisation control and Bently Nevada vibration monitoring system including complete MCC fit out and installation of power distribution, VESDA, Purfil Systems, UPS, ABB AC800 DCS, ACS800 & ACS355 VSD's, Siemens turbine/generator set control, HV switchgear & engineering station, instrumentation and commissioning.

    Duration: 12 months
    Staff: 25
    I/O count: 400

  • Paper Mill Starch Silos Haz Ex Safety Upgrade

    Project requirements - removal, replacement, relocation and modification of plant & equipment located within a 'Hazardous Area' operating environment.

    Works included -

    • Creation of site area dossier and validation of the customers procured equipment against the site classification documentation, IECex certificates, ANZex/AUSex and current Australian standards for compliance
    • Replacement of existing motors, field sensing devices, transmitters, indicators, beacons, 3 Phase outlets, lighting, control panels, field isolator switches, ground monitoring unit, dust collector stop/start control stations with Ex-tD rated components
    • Installation/replacement of phase loss protection, Emergency Stop Switches, , intrinsically safe (I.S.) indicator units, new earth bonding conductors
    • Replacement of motors with phase loss protection, Field sensing devices, radar transmitters, pressure transmitters, weight indicators, indicating beacons, power outlets, lighting, control panels, field isolator switches, ground monitoring units and push button stations with Ex-tD, Ex-Ia/b, Ex-e, Ex-n rated components
    • Testing, dry/wet commissioning and H-class inspections of equipment to comply with current Australian standards including ITP, ITR, commissioning calibration, earth bond resistance and COES documentation.

    Duration: 5 months
    Staff: 6