Detailed designs, specifications and drawings for a new electrical reticulation and control system on Dragline 5.  Designs included interfacing for a GE PLC system, static field exciters, re-wiring of the whole machine, installation of a new control room and overhauling of the existing AC and DC motors.

Involving the development of fundamental design of the Control System for the new CHPP facility utilising latest PLC and HMI software products. Interacted with client project management and vendors for the tender and purchasing of equipment for the control system design and ensuring contracts are managed and met accordingly to specifications.

Upgrading SCADA system to Citect v7.10 and completing RSLogix 5000 and Citect programming for Overland Conveyor project.  Provided technical assistance for ControlLogix and SLC 500 programming and Citect configuration.

The Power Study of Rio Tinto's Hail Creek Project incorporated a Protection and co-ordination study as well as an  Arc Flash study for all equipment on site.  Arc Flash labels for every switchboard on site showing category ratings and PPE requirements were developed and installed to aid electrical personnel.  Cell Consultancy offered a whole of service approach for this project which incorporated everything from an initial site audit through to updating site documentation and implementing recommended protection settings.  Cell manage and maintain the protection systems for the client. The system was implemented on time and on budget meeting all of the clients expectations.

This study involved single line diagram updates, fault level calculations, arc flash calculations, time current curves and a protection setting matrix. A detailed report provided protection setting changes and arc flash results.  Arc Flash labels were provided for all switchboards on site to aid electrical personnel in determining risks associated with accessing or operating switchgear.

BMA required a solution for the reduction of Arc Flash levels likely to be encountered on the main 415V bus of the CHPP MCC's. This process involved evaluating a number of options in consultation with the Mine to determine the best solution.  A solution was found in the form of a CB which offered quick response times to fault levels.  It was proven that under all expected fault conditions for the system, a Category 1 could be maintained.  Complicated processes and detection systems were avoided on this design.

The existing 30 years + MCC's used on site were to be bought up to present standards of safety with modern design options included.  Cell Consultancy investigated a number of technology pathways which could be implemented.  With the results of the analysis, we were able to design and procure new state of the art MCC's which payed particular attention to arc flash mitigation and control, functionality and fault finding capability, and equipment footprint reduction to allow for future expansions.

Existing earth grids on site required upgrading to ensure step and touch potentials were controlled under fault conditions and to ensure earth grid reliability for expected fault currents. The existing earth grids had passed their serviceable life with signs of deterioration and corrosion.  Cell Consultancy was approached to document the existing systems design and then calculate and design new grid systems to replace or supplement the existing systems.  The new designs were completed and were fully compliant with AS3007 and the CMS&H regulations.

Cell Consultancy was approached to provide engineering solutions for the upgrade of an existing 8MVA transportable substation. New designs were to meet present standards and provide the highest levels of safety and functionality.  For this project Cell produced detailed designs for the new power and control systems which incorporated transformer protection systems, 48VDC control system, PLC interface, remote switching and racking systems and an interface and diagnostic tool. This information along with a detailed supply specification was used to tender the manufacture of the refurbished switchgear.

New Earth Grid designs were developed for Callide Mine's Transportable Substations. For this project, Cell Consultancy went to site to complete soil resistivity tests.  The data was analysed and used to develop new earth grid designs which were fully compliant with AS3007 and the CMS&H regulations.