Distribution boards, motor control and conveyor installation

Overview

Karratha Electrical Group (KEG) delivered a range of electrical distribution, motor control and conveyor installation projects across Rio Tinto Dampier Salt operations in Western Australia.

Works included purpose-built distribution board replacements, a 200 kW conveyor VSD installation, the CV002 conveyor replacement electrical package at Port Hedland, and electrical and instrumentation works for the CV007 stacker replacement at Mistaken Island, Dampier.

Each project required integration with existing infrastructure, tailored installation arrangements and coordination with site operations and other construction teams. KEG’s involvement covered custom switchboard design and supply, electrical installation, testing, commissioning and handover.

Scope of works

Electrical project management, site supervision, shutdown coordination and client reporting.
Design, supply and installation of purpose-built distribution boards and motor control systems.
Custom switchboard configurations to accommodate existing cable lengths, cable entry positions and restricted installation spaces.
Design and installation of stainless steel mounting frames, plinths, brackets and support structures.
Engineering to meet site arc-flash requirements, including equipment identification, arc-flash and PPE labelling.
Installation of circuit protection, site-specific controls and integrated RCD testing facilities.
Installation of a VSD for a 200 kW conveyor system, including associated power and control modifications.
Disconnection, identification, protection and reinstatement of existing electrical services during conveyor and stacker replacement works.
Installation and termination of motor power cables, control wiring, local control stations and junction boxes.
Installation and connection of conveyor protection devices, including pull-wire, belt-drift, belt-rip, underspeed and tilt switches.
MCC marshalling modifications and integration of field equipment with existing control systems.
Rerouting and reconnection of radial stacker power, control and fibre-optic cabling.
Installation of pulley-bearing vibration and temperature sensors, instrument cabling and monitoring junction boxes.
Installation of conveyor lighting, start-up warning systems, washbox solenoid connections and ancillary electrical services.
Coordination of underground cable routes with civil contractors, including conduit installation, cable ladder modifications and earthing.
Electrical testing, point-to-point checks, insulation resistance testing, motor rotation checks and field-device verification.
Assistance with PLC input/output testing, functional checks and dry and wet commissioning.
Preparation of electrical red-line drawings, testing records and handover documentation.

Outcomes

Delivered electrical infrastructure upgrades across multiple Dampier Salt operations.
Integrated purpose-built switchboards and motor control equipment with existing site infrastructure.
Accommodated established cable lengths and installation constraints, minimising unnecessary cabling alterations.
Completed electrical packages supporting major conveyor and stacker replacement projects.
Installed conveyor protection, warning and condition-monitoring equipment to support operation and maintenance.
Delivered tested electrical installations and commissioning support for the return to service of critical salt-handling assets.

Gallery

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Rio Tinto – Dampier Salt

Distribution boards, motor control and conveyor installation

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Get in touch

Let’s talk about your electrical requirements.

From new projects and upgrades to maintenance and technical support, talk to KEG about what your site needs.