Sinewave Electrical Contractors

Installation of three new drives for the automation of two feed conveyors for the loading of the iron ore fines train, to replace an existing, outdated hydraulic system, which was too slow and unreliable.
The scope of work included a PDL UDI-340 VVVF with braking resistor, extensive cable tray work at height, and all necessary control wiring from the field to marshalling and the PLC.

Working in accordance with train schedules.
Working on a confined structure at height, with engineering companies, sandblasters and painters also working to a tight schedule.
Performing all preparation work on an operating part of the plant, with trains continuing to be loaded.

Project Challenges:

The need to design and install a system to keep the camera lens clean at all times. (This was achieved by installing the cameras in sealed boxes and connecting large air dryers to combat the build-up of dust.)

Working at heights in a wet and dusty environment.

The need to experiment with switching devices such infrared and micro switch before corning up with a reliable unit that would work in the harsh environment.

Project Challenges:

Working within operating streets, traffic control.

Locating and protecting all existing underground services, power, water and phone.

Excavating across residential roads, with a 30 ton excavator, completing up to 10 house crossings a day, installing conduits, back filling trenches with stabilizing sand and making site safe before finishing each day to ensure premises were accessible and safe for the public.

Locating existing house mains, digging holes by hand to un-cover cables so that on change over day isolations were kept to a minimum but without compromising our people's safety.

Protecting the residence by placing large metal plates over all excavations, street crossings and house sub-mains by daily finish.

Keeping the same working crew for the entire project, despite working through Pilbara summer conditions, repetitive scope of works and close proximity to traffic and the public.

Project Challenges:

The project required some 30 personnel split over day & night shifts, half of whom were from Perth.

The project only had 3 work fronts which limited manning.

80% if the works could not be started until the isolation was placed during the shutdown phase of the plant.

Most of the existing cables where aluminum and required extensions to reach the new MCC connection points, this was made possible by copper flex cables and bi-metal crimps.

All existing control was updated to Semiens / Profibus type indication so all old interposing technologies and wiring were replaced during the shutdown.

Project Challenges:

Due to the old panels being constructed of asbestos, strict asbestos handling procedures were put in place, where samples were taken from all old panels, documented and sent for professional analyzing. Each housing panel was also photographed.

The co-ordination of each days work was the hardest component as their was a mix of people being on holidays, on night shift or away on other works.

Due to the age of the existing electrical installations (most residence were built in the 70's), once the houses were energized it was common for faults to occur, these faults needed to be cleared ASAP.

Keeping a crew motivated for 18 months, to complete the same work on a daily basis was a great challenge to management, who handled it very well.

ummer in the Pilbara Region reaches 50° easily on some days, so clearing faults inside confined tin roof spaces was a great challenge.

Project Challenges:

The remote location of the site challenged accommodation for our people on the job.

Hours required to be worked by employees on a daily basis were long and were during hot summer temperatures, this was a major challenge for management on the job due to employees health needed to be strictly monitored for fatigue.

Project Accomplishments:

Completing nearly 1500 man hours with zero safety incidents.

Successfully participating in numerous Pilbara Iron Health & Safety audits with a very positive response from the client.

Completing the job successfully with zero dedicated plant shutdown time.

Providing commissioning support for client plc interface.

Successfully liaising between three different Mine Resource Units and the client to keep the project moving forward.

Completing all works to such a high standard that the project punch list was minimal.

Completing works to a standard that we have been invited to work with the client on future projects.

Projects


Client: Hamersley Iron	Train Loadout Upgrade
Location: Tom Price - Pilbara
Date Awarded: 30/10/2000
Date Completed: 15/12/2000	Scope Of Works:
	Installation of three new drives for the automation of two feed conveyors for the loading of the iron ore fines train, to replace an existing, outdated hydraulic system, which was too slow and unreliable. The scope of work included a PDL UDI-340 VVVF with braking resistor, extensive cable tray work at height, and all necessary control wiring from the field to marshalling and the PLC. Project Challenges: Working in accordance with train schedules. Working on a confined structure at height, with engineering companies, sandblasters and painters also working to a tight schedule. Performing all preparation work on an operating part of the plant, with trains continuing to be loaded.

Client: Hamersley Iron	WIP Frag
Location: Tom Price - Pilbara
Date Awarded: 11/06/2000
Date Completed: 07/07/2000	Scope Of Works:
	Installation of high quality lumina lighting above the haul truck tip head into the primary crusher. Design and installation of a microwave switch system to activate specialised cameras for data collection and analysis. Installation of a fibre optic network link for the camera system. Project Challenges: The need to design and install a system to keep the camera lens clean at all times. (This was achieved by installing the cameras in sealed boxes and connecting large air dryers to combat the build-up of dust.) Working at heights in a wet and dusty environment. The need to experiment with switching devices such infrared and micro switch before corning up with a reliable unit that would work in the harsh environment.

Client: Pilbara Iron	Dampier Street Mains Replacement
Location: Dampier - Pilbara
Date Awarded: 2001
Date Completed: 2002	Scope Of Works:
Project Value: $4.5m Fixed Sum	To help Pilbara Iron (member of RioTinto) meets its regulatory requirements in limiting power black outs to its power supply supplying the community of Dampier. To carry out excavation works within 38 streets, to replace all existing street mains cabling while in control of traffic, pedestrians and multiple street crossings. Terminate universal pillars, connection of 150mm cables to existing old transformer switching devices. To carry out all required excavation works between street pillars to individual mini pillars at each house lot, 350 dwellings. New 10 mm sub-mains to be tied into existing buried sub-mains. For final change over to new supply system, only being allowed a 4 hours window for isolations to each street change over. For all required co-ordination between tenants to keep them informed of digging on their premises & within their street, times for power outages and change overs. Project Challenges: Working within operating streets, traffic control. Locating and protecting all existing underground services, power, water and phone. Excavating across residential roads, with a 30 ton excavator, completing up to 10 house crossings a day, installing conduits, back filling trenches with stabilizing sand and making site safe before finishing each day to ensure premises were accessible and safe for the public. Locating existing house mains, digging holes by hand to un-cover cables so that on change over day isolations were kept to a minimum but without compromising our people's safety. Protecting the residence by placing large metal plates over all excavations, street crossings and house sub-mains by daily finish. Keeping the same working crew for the entire project, despite working through Pilbara summer conditions, repetitive scope of works and close proximity to traffic and the public.



Client: Pilbara Iron	MCC Change Out
Location: Tom Price Process Plant
Date Awarded: 2004
Date Completed: 2004	Scope Of Works:
Project Value: $1.5m Do & Charge	To replace an aging and outdated motor control center (MCC) within an operating process plant, the MCC controlled and protected some 200+ drives, motors and pumps. The MCC was the heart of the Tom Price Iron Ore process plant, so only a very tight down time was allowed. The change out become the critical path item during a 2 week major shut down. All field cabling had to be traced, labeled and marked for new destinations. The old MCC had to be disassembled to manageable modules, then fitted with skates and rolled out through a modified entrance onto a special scaffold platform, where a crane could be used to remove each module. The sub-station that houses the MCC is 3 stories in height. The preparation works to ensure a smooth change over took 2 months of planning and communication. As part of the scope, existing aluminum mains cables that supplied the 2000 AMPS to the MCC bus bars had to be replaced with 300mm copper flex cables, 7 per phase. This work could only be completed during the shutdown phase. Project Challenges: The project required some 30 personnel split over day & night shifts, half of whom were from Perth. The project only had 3 work fronts which limited manning. 80% if the works could not be started until the isolation was placed during the shutdown phase of the plant. Most of the existing cables where aluminum and required extensions to reach the new MCC connection points, this was made possible by copper flex cables and bi-metal crimps. All existing control was updated to Semiens / Profibus type indication so all old interposing technologies and wiring were replaced during the shutdown.



		Old MCC	New MCC

Client: Pilbara Iron	RCD Project
Location: Tom Price & Paraburdoo
Date Awarded: 2005
Date Completed: 2006	Scope Of Works:
Project Value: $3m Agreed Value	Pilbara Iron as the power authority of Tom Price and Paraburdoo in the Pilbara Region of WA, had a legal obligation to bring its employees housing up to date with the latest regulations and standards, as most did not have any residual current devices (RCD) fitted. The project covered some 1800 houses throughout the two townships. Sinewave's scope of work was to install a weather proof surface mounted switchboard beside existing old asbestos panels and install RCDs to both light and power circuits. Upon completion of the installations at each residence, full testing procedures took place before officially handing control of the premises back to the tenant. The project took some 18 months to complete, requiring 4 electricians full time and a supervisor to co-ordinate each days works in advance to ensure work progressed smoothly. he project was completed 1 week ahead of the agreed schedule for hand over. Project Challenges: Due to the old panels being constructed of asbestos, strict asbestos handling procedures were put in place, where samples were taken from all old panels, documented and sent for professional analyzing. Each housing panel was also photographed. The co-ordination of each days work was the hardest component as their was a mix of people being on holidays, on night shift or away on other works. Due to the age of the existing electrical installations (most residence were built in the 70's), once the houses were energized it was common for faults to occur, these faults needed to be cleared ASAP. Keeping a crew motivated for 18 months, to complete the same work on a daily basis was a great challenge to management, who handled it very well. ummer in the Pilbara Region reaches 50° easily on some days, so clearing faults inside confined tin roof spaces was a great challenge.


Client: Pilbara Iron	Brockman Truck Shop
Location: Brockman - Pilbara
Date Awarded: 2005
Date Completed: 2005	Scope Of Works:
Project Value: $800,000	The electrical and communication installation of a new 4 bay heavy equipment workshop. Scope of work included, lighting design and installation in all workshop bays and area lighting. Installation of fibre / data system to a large office space area. Incoming mains cable and main distribution board. All accessories, such as oil, lube and greasing systems. Installation of overhead crane. Project Challenges: The remote location of the site challenged accommodation for our people on the job. Hours required to be worked by employees on a daily basis were long and were during hot summer temperatures, this was a major challenge for management on the job due to employees health needed to be strictly monitored for fatigue.



Client: Pilbara Iron Exploration	Telemetry Pump Control Stations
Location: Bungaroo - Pilbara
Date Awarded: 2007
Date Completed: 2007	Scope Of Works:
Project Value: $300,000 Do & Charge	To design and manufacture a portable telemetry pump control system to operate bore and tank water pumps for remote exploration sites. Systems to be controlled by radio from exploration drill rigs. Units to be self sufficient and solar powered. 14 units to be supplied, all units work in pairs, 1 unit positioned near the water source and the control unit placed near exploration rigs. Project Challenges: Remote locations for installations and testing works. Extreme temperatures with no natural shaded areas No previous designs of the systems, so the system was designed from scratch.



Client: HPS Environmental	Dust Collector B Upgrade
Location: Pilbara Iron - Tom Price
Date Awarded: 2007
Date Completed: 2007	Scope Of Works:
Project Value: $800,000 Agreed	Decommission and remove existing three bag dust collection system. Dust Collector - Supply & install; - all cabling for new five cell reverse pulse dust collection system, - cabling & fixtures for area & walkway lighting, - cabling & fittings for area general purpose power, - cabling for new 180kw drive fan motors, - cable ladder and steel conduits for complete electrical installation, - 11 x new MCC draws for existing MCC installation, - field isolators for new dust collector, - all control wiring required including MCC terminations and fly wiring to the plc, New Pump House - Supply and install; - all cable ladder and steel conduit for pump house, - all new cables required for new pump installation, - new field isolators for new pump installation, Testing and commissioning for all new installations. Project Accomplishments: Completing nearly 1500 man hours with zero safety incidents. Successfully participating in numerous Pilbara Iron Health & Safety audits with a very positive response from the client. Completing the job successfully with zero dedicated plant shutdown time. Providing commissioning support for client plc interface. Successfully liaising between three different Mine Resource Units and the client to keep the project moving forward. Completing all works to such a high standard that the project punch list was minimal. Completing works to a standard that we have been invited to work with the client on future projects.

Projects

Scope Of Works:

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Project Value: $4.5m Fixed Sum

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Scope Of Works:

Project Value: $1.5m Do & Charge

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Scope Of Works:

Project Value: $3m Agreed Value

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Scope Of Works:

Project Value: $800,000

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Scope Of Works:

Project Value: $300,000 Do & Charge

Project Challenges:

Scope Of Works:

Project Value: $800,000 Agreed

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