Instrumentation

  • 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.

  • 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

     

  • 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

  • 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

  • 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