Industrial Engineering

Incitec Pivot’s Phosphate Hill site required replacement of tripping supplies for HV switchboards within its Ammonia Plant, Central Services, Phosphoric Acid Plant, Granulation Plant and Beneficiation Plant. 

The switchboards had a dedicated 110VDC tripping supply with battery backup to power the HV protection relays and provide tripping supply power to HV circuit breakers. Without this back-up supply, circuit breakers would not open in the event of an electrical fault which could result in a catastrophic switchroom fire. 

Existing tripping supplies were approaching end of life and with component failure likely to increase it was proposed to replace the tripping supplies during suitable shutdowns.  

Orana Engineering was engaged to complete engineering design and to provide design drawings ‘issued for construction’. The Orana Engineering-assigned project manager had responsibility for vendor engagement, liaison with site planning and procurement personnel and site attendance during installation, commissioning and construction stages.

Incitec Pivot was looking to replace an existing turbine generator pole slip relay unit at its Phosphate Hill Power Station.  Existing pole slip relays had become obsolete and were at the end of their expected life. Pole slip relays perform a critical protection function for turbine generators and operation of a generator without its pole slip relay would pose an unacceptable risk. Consequences of relay failure on turbine generators would be multiple gas turbines being unserviceable and resulting in power shortages across the site. 

The project scope involved replacement of Multilin 489 protection relay with new Multilin 889 for a 4.5MW gas turbine generator as well as integration of pole slip protection and a synchronisation check facility into the Multilin 889. 

Orana Engineering’s input for the project included electrical engineering design, protection configuration, on site project management and commissioning.

To reduce the likelihood of potential spills in the sulphuric acid unloading area at its Phosphate Hill site, and to prevent consequential environmental and health and safety impacts, Incitec Pivot sought assistance from Orana Engineering with an upgrade of existing acid unloading leak detection and CCTV systems.

In consultation with Phosphate Hill site stakeholder personnel, Orana Engineering conducted an evaluation of available mitigation scenarios before recommending electrical and control methods which were considered to be the most cost effective resolution. Orana Engineering drafting personnel also produced detailed design drawings for the acid unloading leak detection and CCTV upgrade works.

Incitec Pivot’s Phosphate Hill site contacted Orana Engineering to request assistance with evaluation of its Monument Aerodrome runway and apron lighting system following a review of potential electrical hazards.

An assessment of the airport lighting installation was undertaken by Orana Engineering electrical engineering personnel with findings presented to the client in report format. Review considerations included reference to CASA and Australian Standards and outlined a high level risk assessment conducted to quantify electrical safety risks.

Following client consideration of recommendations, Orana Engineering provided front end loading (FEL 3) documentation for replacement of existing runway and taxiway lights, series isolation transformers and the existing lighting control system.  A scope of work was then prepared with the tender process managed by Orana Engineering on behalf of the client for the appointment of a specialist airport lighting contractor to complete design and construction of the lighting and control system upgrades. 

Incitec Pivot contacted Orana Engineering for assistance in identifying options for upgrading its Mount Isa Acid Plant Electrostatic Mist Precipitators (EMP). This was primarily to mitigate issues with EMP 7 and 8 which were contributing to low dust capture efficiencies, converter catalyst degradation and potentially premature damage to tube bundles.

Orana Engineering electrical engineering personnel sourced additional information on issues experienced and liaised with equipment manufacturers for recommended solutions.  A design review table was prepared to summarise and document data from previous reviews including reports, tests, inspections and previous recommendations. 

Orana Engineering provided offsite assistance in co-ordinating procurement and installation with deliverables to the client comprising the finalised design review summary table, BOM, equipment quotes and redline drawing mark-ups for upgrade of the EMP controller.

Package boilers at Incitec Pivot’s Phosphate Hill mine were unserviceable to operating challenges. To compensate, low pressure steam supply was being supplemented from the power station. Phosphate Hill required return of the low pressure steam supply to site and back to full reliability to allow improved steam export to its Phos Acid Evaporation Circuit.

The new boiler was to be a 10MW unit with an automated water treatment system to maintain correct chemical dosing rates and reduce corrosion, thereby improving long term reliability.

The scope of Orana Engineering’s engagement was provision of electrical engineering site assistance associated with replacement of the existing package boiler for new, replacement of boiler feedwater pumps, combustion air fan and control panel. Additionally, automation of the chemical dosing system, instrument replacements, co-ordination of Type B gas appliance approvals and commissioning was provided.

CSE Energy’s Kogan Creek Power Station identified that due to higher than normal rainfall its decant pond had neared capacity and was unlikely to evaporate in an acceptable timeframe by either natural means or with the assistance of fans. It was proposed to reuse the water on site, however due to a concentration of suspended silt the decant water required treatment before being returned to the plant. The solution was sourcing and installation of a containerised water clarification plant.

Orana Engineering was contacted for provision of electrical engineering design and support for power and control of the proposed ash water treatment facility as well as mechanical engineering input with pumping, piping and tank design for water supply and tie-in to existing infrastructure.

At the request of Carborough Downs Coal, Orana Engineering initiated an investigation into an upgrade of dewatering and sump transfer systems for multiple underground and surface mining areas at the then Vale-owned mine. Existing pumping systems were deemed not fit for purpose and the client required options for solutions capable of handling projected maximum rainfall and underground water-make intensities and preventing ingress of water to mine workings during such events.

In addition, Orana Engineering was requested to formulate a concept design for dewatering of underground workings during longwall mining operations and to offer alternatives to the existing system.

At the conclusion of investigations, the client was provided with various concept designs for both surface and underground dewatering options along with equipment recommendations and budget estimates.

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.

The mother beam of the 40T ship loading crane at the Port of Townsville was nearing the end of its 30 year service life. Xstrata Copper engaged Orana Engineering to redesign the beam based on the existing beam and to incorporate changes in compliance with latest regulations.

After fully modelling the mother beam using Autodesk Inventor, RPEQ approved shop detail drawings were produced. Electrical monitoring systems were introduced to enable crane operators to confirm when the mother beam was fully engaged with various attachments, and control wiring to the beam was redesigned to include two cable drums whereas the original had three.

Mechanical redesign included a failsafe back-up locking system and design improvements highlighted by feedback from maintenance personnel.

Melbourne Bio Diesel’s James Cook University research facility required an elevated level area for installation of fresh sea water storage tanks. Orana Engineering was requested to design a solution that increased efficiency with tank drainage and improved safety around the tanks.

A site visit was performed to gather measurements of the nominated tank farm area. This included identifying trees requiring removal and determining required tank heights and current ground levels. From the information gathered Orana Engineering used AutoCAD to model ground levels and the amount of fill required to lift tanks to a suitable level for gravity drainage. The design incorporated a conical base on each tank for drainage and the introduction of buried control valves accessible via covered pits.

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.