Electrical Engineering Consultants

APA Group released a project for tender comprising electrical and instrumentation for rectification of hazardous area compliance issues.  Condamine Electric Company (CEC) tendered on the work and engaged Orana Engineering to prepare a detailed estimate of costs to complete the rectification works. Orana Engineering undertook a detailed review of the scope and drawings in the tender package to ascertain requirements.  Quotes for non-standard equipment were obtained and a detailed cost estimate was created. Additionally, from the scope review Orana Engineering identified and compiled a comprehensive list of questions which were subsequently raised by CEC during a tender site visit.  Upon provision of responses, Orana Engineering delivered a complete capital estimate to CEC for tendering.

Prime Pump Company was contracted by Origin Energy and Laing O’Rourke to supply an upgraded bore pumping system at Origin’s Combabula site. RIE Services was contracted by Prime Pump Company to supply and install electrical components for the upgrade, with Orana Engineering subsequently engaged by RIE Services to complete a fault protection study on the new installation. Using SKM Power Tools for Windows software and manual calculation techniques for verification, together with information from RIE and Prime Pump Company, Orana Engineering produced an HV/LV model calculating fault levels and completing a protection co-ordination study.  From the study it was recommended a new circuit breaker be introduced to protect the transformer, variable speed drive and supply cables.

At James Cook University, MBD Energy operates a research facility investigating methods of cultivating and harvesting algae. To facilitate greater control of the algae agitation sleds, Orana Engineering was engaged to design and commission mechanical, electrical and control systems that would enable agitation sled velocity and frequency of travel to be automated. The system was designed and implemented by Orana Engineering utilising Allen Bradley Powerflex VVVF drives and a Controllogix’s PLC with an RSView SCADA interface. Orana Engineering was able to help MBD Energy improve the efficiency and quality of their research results by providing technical knowledge and assistance through our control systems, electrical engineering and mechanical engineering services.

Oaky Creek Coal engaged Orana Engineering to perform electrical and control system design aspects of a 22M Flyover Conveyor to provide an interface between two existing conveyor systems. Orana Engineering’s brownfield engineering expertise was drawn upon to resolve complexities in interfacing two different coal streams, powered from separate substations and controlled from independent process control systems. Should one system need to be shutdown it was necessary that the other system was not impacted. The electrical engineering scope included powering the conveyor and transfer systems and providing lighting designs and power distribution. Control system engineering included selection and specification of instrumentation, specification of control system hardware and development of a functional specification.

Vale at Carborough Downs Coal Mine required quantifying of current and possible future capacities of product conveyors at their coal processing plant in Central Queensland and high level recommendations to achieve increased plant tonnages. Orana Engineering completed an initial site visit to gather the necessary information for review of each of the conveyors. Engineering checks were completed to identify ‘bottle-necks’ in the conveyor design such as motor power, drive equipment, belt curves, GTU mass, belt speed, belt capacity, belt tensions and electrical supply. Orana Engineering issued a detailed report at completion of the study and provided concept level equipment modification recommendations for tonnage ranges advised by Carborough Downs Coal Mine.

For site consistency of electrical design and installation standards and compliance with Australian standards and legislation, Glencore Oaky Creek Coal engaged Orana Engineering to prepare new site electrical specifications. The scope combined existing site specifications and practices and, where applicable, incorporated them into the new specifications. These specifications included:

• Electrical Design
• Electrical Installation 
• Preferred Electrical Equipment List
• Site Equipment Numbering
• Drawing Management

Orana Engineering’s extensive knowledge of Queensland mine sites and long-standing experience at Oaky Creek enabled specifications to be produced cost effectively and fully inclusive of site specific details. Orana Engineering continues to maintain these documents for Oaky Creek Coal, ensuring that latest versions are readily available to site personnel via Oaky Creek’s drawing management system.

To increase the efficiency of their concentrator, Eloise Copper Mine enlisted Orana Engineering to provide engineering and design assistance with installation of three copper concentrate scavenger cells within the existing plant. 3D models created by Orana Engineering designers were used to visually communicate solutions for new and existing equipment locations and structure arrangements. Detailing of these concept models enabled Orana Engineering to identify key tie-in locations within the plant for survey during the detailed design phase. A multidisciplinary approach during detailed design ensured improved efficiency, with brownfield engineering challenges in relocating / connecting to existing equipment successfully achieved. Upon design completion the client was provided with an installation drawing set and scope of work.

The purpose of the Reagent System Upgrade at Oaky Creek was installation of new reagent storage tanks, discharge / delivery pumping systems and automated flow control distribution manifolds for the delivery of each reagent to the nominated process connections. Orana Engineering performed mechanical, electrical and control systems design, drafting and engineering for the project. The primary deliverables included scope of works, construction drawings, functional specification, BOM, spares lists and equipment / instrument data sheets. Orana Engineering managed the onsite commissioning of the system and provided a system handover to operations for implementation. An Operation & Maintenance Manual and Hazardous Area Dossier were provided on project completion.

For personnel safety and compliance with Queensland’s Coal Mining Safety & Health Regulation it is a requirement for mine sites to provide electrical workers with access to up-to-date drawings for electrical equipment and electrical installations. To improve the maintainability of plant electrical systems and personnel safety, Hail Creek Mine engaged Orana Engineering to create bound books of electrical drawings for Draglines 1 and 7 and Shovel 14. Multiple books were made for each machine in both A4 and A3 sizes and using waxed (water proof) paper to ensure longevity. Using vendor drawings from the client, Orana Engineering produced bound books containing all electrical power, control and termination diagrams associated with the respective mobile plant.

Orana Engineering was engaged by Oaky Creek Coal to assist in design and construction of onsite camp accommodation, including an HV substation for power and potable water supply. Our brief included mechanical, electrical and control systems design, drafting and engineering for the project. Deliverables included scope of works, construction drawings, functional specification, drawing and equipment registers, commissioning and operating spares lists and equipment and instrument data sheets. Orana Engineering provided PLC configuration and commissioning assistance for pump control, acted as Client Representative during construction, managed onsite commissioning of the system, and provided a handover to operations for implementation. Operation & Maintenance Manuals for potable water storage and the HV substation were provided upon completion.

Following commissioning of their Process Water Reverse Osmosis (RO) Plant, Oaky Creek Coal received approximately 150 electrical drawings from the vendor. To provide site personnel with access to the drawings, Oaky Creek engaged Orana Engineering to register these within their existing drawing management system. There are many drawing management systems and tools on the market and Orana Engineering has the capabilities and resources to utilise whatever system is preferred by a client. Oaky Creek Coal sets a very high standard in the industry for the maintenance of drawings and in real terms realises the significant cost benefits that good drawing management delivers in enabling site personnel to perform effectively and safely.

To ensure the CHPP reagent tank farm lighting protection systems complied with Australian Standards, Moranbah North requested Orana Engineering to undertake a review and design an upgrade of the lightning protection systems for the tank farm area. With the area encompassing fuel storage tanks, it was classified as having structures with "explosive or highly flammable contents" and was therefore required to comply with AS1768 : 2008 Lightning Protection. Orana Engineering’s audit of the installation and its lightning protection systems confirmed that an upgrade of the facility was needed to comply with current lightning protection standards. Using its team of detailed draftsmen Orana Engineering created a set of drawings detailing the work required to comply with AS1768 : 2008 Lightning Protection.

To improve the maintainability of plant electrical systems and personnel safety, Hail Creek Mine employed the drawing revision services of Orana Engineering to redraw electrical power, control and termination diagrams associated with its Dragline 7 into AutoCAD format. Having electrical drawings in CAD (computer aided design) format, is one of the most efficient ways to capture site electrical modifications, installations or as-building changes for ready access by site personnel involved in maintenance and operations. Working closely with site contacts and onsite electricians, Orana Engineering was able to accurately reproduce 247 electrical drawings into AutoCAD for Dragline 7.

To ensure plant maintainability and personnel safety, Dyno Nobel employed Orana Engineering to redraw its low voltage and high voltage single line diagrams, while also confirming their accuracy and functionality. Through the use of client photos, documentation and discussions Orana Engineering was able to accurately redraw 52 low voltage single line diagrams as well as 6 high voltage single line diagrams. During the redraw process Orana Engineering identified that a larger size drawing template was required to ensure critical information was easily readable on a single drawing. An A0 size drawing template was designed to meet Dyno Nobel's drawing standards with the template providing links for the document management system to easily access drawing metadata.

To increase productivity and maintain compliance with legislative standards, Glencore Coal employed the services of Orana Engineering to design and manage the electrical aspects of an upgrade to their existing sewage treatment plant. The project was managed on-site by others, with Orana Engineering providing electrical engineering, design, project management and construction / commissioning assistance. Upon completion of installation, Orana Engineering updated all drawings to reflect any changes made, thus providing Glencore Coal with as-built drawings which will make any future maintenance or fault-finding work more efficient and cost effective, as well as providing legislative compliance.

The Coal Handling & Preparation Plant at Oaky Creek Coal utilises a Yokogawa Distributed Control System for control and monitoring of their operation. The system incorporates Yokogawa’s OPC server and Exaquantum data historian. OCC utilises multiple Programmable Logic Controllers for specific operational purposes, with a number of PLCs interfaced back to the DCS for control and monitoring functions. Since 2005, Orana Engineering has provided 24/7 support for Oaky Creek’s control system. Day to day support is provided by remote access, which is cost effective and highly responsive. Additionally, onsite support for hardware solutions and commissioning of larger projects is provided as required.

At the completion of Tailings Pumping Upgrades of the Main CHPP and Module 4 CHPP at Oaky Creek Coal, Orana Engineering received As Built drawings from site and was requested to make electronic revisions for upload into the client’s Drawing Management System. Over 80 drawings had received red pen site mark-ups indicating either that the design had been constructed as per the drawings, or highlighting design changes made during the construction phase of the project. Orana Engineering reviewed these mark-ups and formally revised all drawings to As Built status, incorporating the site mark-ups. The final set of drawings was uploaded to the client’s Drawing Management System ensuring site personnel had access to the latest As Built drawings.

The Glencore Port Operations in Townsville operate an export facility for minerals concentrate and refined copper within the Port of Townsville precinct. The concentrate in-loading rotaside tippler was identified as being at end of life and a feasibility study was commissioned to review a like-for-like replacement option for refurbishment of the tippler. To facilitate feasibility-level costing, Orana Engineering was asked to provide electrical engineering and mechanical engineering assistance with provision of a concept design for the proposed refurbishment and upgrade. By working closely with Glencore, and other consultants engaged on the project, Orana Engineering was able to contribute as part of a collective "owners engineering team" to the feasibility assessment of a significant engineering project in the Townsville Region.

Due to expanding operations, Oaky North underground operations saw benefit in having an underground workshop and refuelling stations to reduce vehicle travel times and increase efficiencies. Orana Engineering was engaged to provide concept design and estimating assistance for project approval. From communications with our client, Orana Engineering prepared concept general arrangement drawings for consideration. Based on these concept design drawings, a project capital estimate and project schedule were prepared for Oaky North underground operations. From the information presented by Orana Engineering, Oaky North could accurately consider whether the underground workshop was feasible, and ensure that appropriate budgets and project planning was completed at the concept design phase to improve confidence in the project prior to execution.

Since 2005, Orana Engineering has provided 24/7 support for Oaky Creek Coal control systems. At the coal handling and preparation plant, a Yokogawa DCS installed in 1998, is used as the primary control system. With existing CentumCS Unix software no longer supported by Yokogawa, it was essential to complete an upgrade to the CentumCS3000 system. Orana Engineering developed conversion tools to allow configuration data to be extracted from the CentumCS Unix platform and imported into the CentumCS3000 environment. These tools provided efficiency and accuracy for the conversion and delivered a significant cost saving. The quality of conversion tools and simulation programs developed by Orana Engineering resulted in highly efficient site commissioning, completed without plant downtime.