Water Treatment

 

Wastewater Plant A & B - Hope Downs 1

Megatronic Power Systems has recently finished the electrical and control system upgrade works for both wastewater treatment plants A & B at Hope Downs 1 Village. Hope Downs 1 village is a 400-man camp which caters for Rio Tinto’s Hope Downs 1 mine site. This was a brownfields project for Megatronic and as such the facility had to remain operational at all times. The wastewater electrical infrastructure was old and in poor condition. The plants themselves had a high downtime rate and required a lot of intervention and local monitoring from the maintenance personnel.

This project included a revamp of the sites electrical and control infrastructure, including:

  • x2 new electrical control panels
  • x2 new PLC’s – re-write the old logic into the new software with major improvement works
  • x2 HMI interfaces with local alarm pages and status of the facility
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the plants onto a new sitewide SCADA system with remote monitoring and control.

The project was a major success as it has dramatically reduced the downtime of each facility and gives the maintenance staff remote visibility and control of their asset.

Village Bore-Field Water System - Hope Downs 1

Megatronic Power Systems has recently finished the electrical and control system upgrade works for Hope Downs 1 Village Bore-fields water system. The Bore-fields are the only source of water for the 400-man village and feed raw water to the treatment tanks. The Bore-field electrical infrastructure was old and the control system was unreliable. The raw water tank was running low on a weekly basis. There were no drawings available for maintenance staff and it required a lot of resources from the maintenance team. This was a critical brownfields project for Megatronic and as such the facility had to be operational at all times. The Project consisted of:

  • x3 new electrical control panels
  • x3 new PLC’s – re-write the old logic into the new software with major improvement works
  • x3 HMI interfaces with local alarm pages and status of the facility
  • New instrumentation
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the bore-field system onto a new sitewide SCADA system with remote monitoring and control.

The completion of Megatronic Power Systems scope of work seen a dramatic increase in reliability. The Village raw water supply is now constantly controlled to ensure the appropriate stocks are maintained.

Village Potable Water Treatment System - Hope Downs 1

Megatronic Power Systems was awarded the contract for an electrical and control system upgrade at Hope Downs 1 village potable water system. The potable water system includes Potable water tanks, a Chlorine dosing system, a Calgon dosing system and x3 distribution pumps which maintain the water supply to the village.

This project included a revamp of the sites electrical and control infrastructure, including:

  • x3 new electrical control panels
  • x3 new PLC’s – re-write the old logic into the new software with major improvement works
  • x3 HMI interfaces with local alarm pages and status of the facility
  • New instrumentation
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the Potable water treatment including Chlorine dosing, Filtration, and 5 Tanks onto a new sitewide SCADA system with remote monitoring and control.

This project was a brownfields project. Megatronic’s precision planning, project management and communication ensured that there were no water outages during the course of the works.

Potable Water Pumps – Brockman 2

Megatronic Power System was asked to go to site and investigate some issues on the potable water distribution system at Brockman 2 village. Both potable water pumps were experiencing difficulties and the camp pressure was not being maintained/controlled. This was resulting in periods of low pressure / no water and also periods of high pressure which caused water leaks across the village infrastructure. Only one pump had been in service and the control system had flaws and diagnostic issues. The system was in a critical state.

The system was not configured correctly and the control system was not monitoring the line pressure to control the pumps. There were little diagnostics features available and the setpoint function did not respond to allow the maintenance personnel to modify the line pressure. Megatronic reconfigured and programmed the system. Megatronic also upgraded the instrumentation and conducted training for the system.

The project was a major success for the team. The pumps are maintaining the correct pressure. Maintenance personnel can now easily maintain the system and adjust the setpoints when required. The village infrastructure is protected, and the water leaks around the village have been dramatically reduced.

Potable Water Pumps Upgrade - Hope Downs 4

Megatronic Power Systems was awarded the contract to conduct electrical and controls system upgrade works at Hope Downs 4 Village potable water pumps station. The Potable water pumps are the most critical piece of infrastructure in the villages water system, as they maintain the water pressure and ensure that there is a constant supply of water to the camp and mine-site. The potable water system had been suffering from frequent outages meaning that Hope downs four village (1000-man camp) and Hope Downs 4 mine-site were without water for extended periods of time. The electrical infrastructure was old and was the system had control issues.

Megatronic designed a new state of the art electrical design with a cutting-edge control system. The system does not suffer from any unplanned downtime, it is remotely monitored and it is easy to maintain. The project included:

  • A new form 4 electrical kiosk/enclosure (double skin) with forced air cooled design (temperature control) to combat the Pilbara environment
  • x1 new PLC
  • x1 HMI interfaces with local alarm pages and status of the facility
  • VSD control for all pumps
  • New instrumentation
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the Potable water pumps onto a new sitewide SCADA system with remote monitoring and control

The completed project insured that there is now a reliable and consistent water supply to both the HD4 village and also the HD4 mine-site.

Potable Water Pumps Upgrade – Punurunah Village

Megatronic Power Systems has recently finished the electrical, control system and mechanical upgrade works for the Potable water pumps. The Potable water pumps are the most critical piece of infrastructure in the village water system as they maintain the water pressure and ensure that there is a constant supply of water to the camp and mine-site.

Three out of four of the potable water pumps had major issues. Only one pump had been in service and the control system had flaws in maintaining pressure and diagnosing issues. The system was in a critical state.

Megatronic was awarded the contract to rectify the issues which included:

  • Supply and install x4 new VSD’s for control for all pumps
  • Review and make major improvements to the PLC logic to control the pumps and share the runtime and extract the required diagnostics data
  • Review and make major improvements to the local HMI to display Diagnostics data and make maintenance an efficient task.
  • Profibus network improvements – bringing VSD’s and Smart Relays data onto the network
  • New instrumentation
  • Mechanical works to supply and install a new 15kw pump

The project was a major success for the team. All four pumps now share the load as required and work together to maintain the water pressure and supply to the village. The HMI has been re-designed so that it's easy to use and the maintenance staff can monitor and control the plant efficiently. The system also displays more diagnostics data and it is now very reliable.

Wastewater Plant A & B - Hope Downs 4

Megatronic Power Systems has recently finished the electrical and control system upgrade works for both wastewater treatment plants A & B at Hope Downs 4 Village. Hope Downs 4 village is a 1000-man camp which caters for Rio Tinto’s Hope Downs 4 mine site. This was a brownfields project for Megatronic and as such, the facility had to be operational at all times. The Wastewater infrastructure was old and in poor condition. The plants themselves had a high downtime rate and required a lot of intervention and local monitoring from maintenance personnel.

Our client noted that the successful project works at Hope Downs 1 had been a major factor in Megatronic being awarded the Project for Hope Downs 4. This project included a revamp of the sites electrical and control infrastructure, including:

  • x2 new electrical control panels
  • x2 new PLC’s – re-write the old logic into the new software with major improvement works
  • x2 HMI interfaces with local alarm pages and status of the facility
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the plants onto a new sitewide SCADA system with remote monitoring and control

The project was a major success as it has dramatically reduced the downtime of each facility and gives the maintenance staff remote visibility and control of their asset.

Village Bore-Field Water System - Hope Downs 4

Megatronic Power Systems has recently finished the electrical and control system upgrade works for Hope Downs 4 Village Bore-fields water system. The Bore-fields are the only source of water for the 1000-man village and feed raw water to the treatment tanks. The Bore-field infrastructure was old and the control system was unreliable. The raw water tank was running low on a weekly basis. There were no drawings available for maintenance staff and it required a lot of resources from the maintenance team. This was a critical brownfields project for Megatronic and as such the facility had to be operational at all times.

Our client noted that the successful project works at Hope Downs 1 had been a major factor in Megatronic being awarded the Project for Hope Downs 4. This project consisted of:

  • x3 new electrical control panels
  • x3 new PLC’s – re-write the old logic into the new software with major improvement works
  • x3 HMI interfaces with local alarm pages and status of the facility
  • New instrumentation
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the borefield system onto a new sitewide SCADA system with remote monitoring and control.

The completion of Megatronic Power Systems scope of work has seen a dramatic increase in reliability. The village raw water supply is now constantly controlled to ensure appropriate stocks are maintained.

Village Potable Water Treatment System - Hope Downs 4

Megatronic Power Systems was awarded the contract for an electrical and control system upgrade at Hope Downs 4 village potable water system. The potable water system includes Potable water tanks, a chlorine dosing system and a filtration system. Our client noted that the successful project works at Hope Downs 1 had been a major factor in Megatronic being awarded the Project for Hope Downs 4.

This project included a revamp of site electrical and control infrastructure:

  • x2 new electrical control panels
  • x2 new PLC’s – re-write the old logic into the new software with major improvement works
  • x2 HMI interfaces with local alarm pages and status of the facility
  • New instrumentation
  • Full electrical design upgrade with installation and commissioning including the drafting and doc control of the design
  • Design and commissioning of a new network backbone and the addition of the potable water treatment including chlorine dosing, filtration, and 5 tanks onto a new sitewide SCADA system with remote monitoring and control.

This project was a brownfields project. Megatronic’s precision planning, project management and communication ensured that there were no water outages during the course of the works.