Our Projects – Page 2 – Southern Cross Switchboards

Onslow Salt Project

Onslow is a coastal town in the Pilbara region of Western Australia, 1,386 kilometres north of Perth. It currently has a population of around 850 people and is in the Shire of Ashburton Local Government Area. Onslow was founded in 1883 as a port at the mouth of the Ashburton River for exporting wool from the sheep stations of the Pilbara hinterland. It was named after the then Chief Justice of Western Australia, Sir Alexander Campbell Onslow (1842–1908).

Onslow has since then become a salt mine with a pond area of 8,600 hectares. It is one of the two salt mines in Western Australia which are owned by Mitsui & Co. With a production capacity of around 2.7 million tons a year, the Onslow salt field provides a steady supply of salt to major chlor-alkali manufacturers in Japan and other Asian countries. It also supplies salt to some food processing markets across Asia.

The Onslow port is also large enough to berth ships up to 55,000 DWT, which makes it an ideal exporter for customers that require larger quantities of salt. A huge facility like this usually has good power backup system. This is where MTU Detroit Diesel came into the picture supplying the generators. Due to the harsh nature of the location, for this project the generators were enclosed inside a shipping containers specially modified to house generators.

In December 2014, Southern Cross Switchboards were given the opportunity to supply two ACB Generator Switchboards and two Auxiliary Control Panels for MTU Detroit Diesel for Onslow Salt. The ACB Generator Switchboards were rated at 3200A at 50kA for 1 second. The Auxiliary Control Panels consisted of a 100A ATS, MCBs and contactors for controlling equipment such as the fuel cooler, the water jack heater, the fuel transfer pump, the ventilation fan & the radiator fan.

This was another project completed with great success by Southern Cross Switchboards.

Value: $71k

Peakhurst Telephone Exchange

Southern Cross Switchboards has recently completed a range of switchboards for the Peakhurst Telephone Exchange project, which is part of the National Broadband Network (NBN) rollout. Among the switchboards are 1 x Main Switchboard, 1 x Standby Generator Plant (SGP) Enclosure and 1 x Mechanical Services Switchboard.

The SGP Enclosure is a simple enclosure that houses an Isolator, which is supplied from a 350kVA Generator Set and feeding the Main Switchboard as the Generator Supply. The Main Switchboard on the other hand is Dual Supply 630A and is constructed to Form 3B as per AS/NZS3439.1 with a Fault Level of 50kA for 1 Second. The outgoing supplies consist of an Automatic Transfer Switch which transfers between the Generator and Mains supplies. The scope of works also included requirements to incorporate Telstra’s Alarm Monitoring System (AMS) in the Main Switchboard. Last but not least, the Mechanical Services Switchboard is a whole new ball game compared to the Main Switchboard. There are lots of control equipment and wiring required.

Similar to most projects associated with the NBN, Peakhurst Telephone Exchange had a very tight time line to completion. This has once again proven to be welcome challenge for Southern Cross Switchboards to complete all three switchboards in the limited time frame given and making sure the quality of the switchboards was not compromised.

Like all things in life, there were several obstacles along the way which set us back but nonetheless, Southern Cross Switchboards still managed to rise to the occasion and complete all three switchboards in the given time frame. Most importantly, we managed to keep our client happy.

Value: $59k

UNSW – Mechanical Services Control Panel

There have been some ongoing refurbishment work at the University of New South Wales (UNSW) and one of the many projects is the installation of new air conditioning system for the computer labs located in the basement of Building K17 Computer Sciences, Kensington Campus.

For this project, Southern Cross supplied a wall mounted enclosure sized W600 x H800 x D200 for the required mechanical services control panel. The lead time for this project is quite short, with the fast approval of the drawings; we managed to get everything going and deliver within the required lead time.

Value: $4k

Seven Hills High School – MSB & DB’s

Seven Hills High School, a member of the Nirimba Collegiate provides education for students from year 7 to year 10. The school aim to provide the best, and successfully develop confident and responsible adolescents. The school organizes diverse range of extra curriculum activities and clubs to encourage students to be active and optimistic towards evolving knowledge and skills.

In 2014, Seven Hills High School had decided to go for an electrical upgrade to reduce electricity demand component cost of an aging system. Southern Cross Switchboards role was to manufacture a new Main Switchboard (Rated at 400A, 30kA for 1 sec), and 2 new switchboards that were to replace the existing switchboards.

The custom built Main Switchboard was located outdoor and rated IP56 with a custom made sloping rain hood. The other 2 switchboards were bit of a design challenge for Southern Cross Switchboards due the unique positioning required within the board for the equipment. The cabling from the disconnected old switchboard into the new boards was a challenge within itself. This was made a lot easier over all with the modification of the switchboard and hence eliminated the connection issues.

Parliament House NSW

Located on the east side of Macquarie Street in Sydney, the Parliament House of NSW was the location of Australia’s first Parliament. This location has substantial history and heritage in NSW.

In this location in 1816, Sydney’s first permanent hospital was established. The 2 original buildings, The Mint building and The Northern Wing (residences for surgeons) are now part of Parliament House. The Legislature occupied building in 1829 and expanded the building over time. The building is now 12 stories high and approximately 42000 sqm.

The current electrical distribution system provides electrical services to Parliament House, Macquarie wing of NSW State Library and Central Plant for chilled and hot water which provides full service for Sydney Hospital, Sydney Eye Hospital and NSW State Library.

Stage 1 – Electrical Upgrade (2015-2016)

The Main Switchboard (MSB) located in Parliament House prior to 2016 needed upgrade. This was an important project because power outages due to downtime on the old MSB could lead to reputational damage, safety responsibility and potential legal liability for NSW Government and Parliament.

Southern Cross Switchboards (SCS) were fortunate to have won the tender to manufacture and deliver:

3 x 3200A Form 3b MSBs to replace the old single MSB
11 x ATS panels
Remote panel enclosure for remote control of breakers.
PM8000 series meter and gateways for all ATS

The major challenge for the installing contractor was that the old MSB, located on level 3 could not be moved without significant planning and preparation due to the risk of substantial downtime to this critical facility. The plan was to migrate services from the 1 off old MSB to 3 new MSBs in stages. The location for the new MSB1 was in position of the old MSB. Extensive co-ordination was done between the installing contractors, NSW Parliament House stakeholders and Southern Cross Switchboards to ensure the installation upgrade flowed through smoothly.

Overall the project was a great success.

Time-lapse video of the construction of the MSBs located here:

https://www.youtube.com/watch?v=-fjtnqP0Kxs

Stage 2 – Addition of the standby generators and electrical upgrade of the Mechanical Services (2017-2018)

In 2015 the client decided to implement 2 new standby generators. For SCS, this stage of project began in 2017 and is to be complete by mid-2018. Southern Cross Switchboards (SCS) were once again fortunate enough to be involved in the switchboard portion of the project. For Southern Cross Switchboards the project included:-

Modification of MSBs manufactured in 2015 to integrate 2 off closed transition ATS systems for Essential and Non-Essential services.
1 x 5000A Form 4a/4b Generator MSB with 2 x 2500A Incomers
3 x New Mechanical Services Switchboards (MSSBs)

The Plant Room located in Level 1 housed the new switchboards for Stage 2 of the project. Once again significant planning and preparation was required to minimize downtime to essential services to this important site. Extensive co-ordination was done between the installing contractors, NSW Parliament House stakeholders and Southern Cross Switchboards to ensure the installation flowed through smoothly.

Compared to Stage 1, the stage 2 portion of works had significantly more onsite works. This was coordinated by our dedicated team by back to back shifts to complete over one weekend.

We are thankful to all involved in making this project successful and look forward to future projects such as this.

Project Value $ 1.3 mil

Clinton’s Toyota Main Switchboard

This project first began in June 2013 and was issued for construction later that month, despite some major design changes due to the particular nature of the site and at the client’s request all the stakeholders worked efficiently to ensure acceptance of the changes didn’t jeopardise delivery. The design was unique and a little different to our standard main switchboard layout for a project of this type.

It incorporates a sizeable distribution board initially designed to be a separate enclosure, however, due to lack of space in the switchroom it was included in the MSB during the approval process. The distribution section comprised of 3 separate MCB chassis with a combined capacity of 192 poles.

We recommended a more economical range of switchgear for our choice of SPD and moulded case circuit breakers, partly chosen for their functionality but mainly due to significant cost savings passed on to the client.

With our flexible and “can do” approach we are confident our client has received a quality product with years of trouble-free operation.

Value $32K

Symantec DB’s

Symantec is a global leader in providing security, storage and systems management solutions for private consumers and small businesses to the largest global organisations.

In March 2014 Stowe Australia undertook a project for the refurbishment of existing office space at levels 6, 11, 12, 13, 14, 16 and 24 at 207 Kent street Sydney.

After only 24 hours to quote the project Southern Cross Switchboards won the project to design and install 6 of the levels Distribution Boards. The scope was to provide an Energy efficient three tier distribution board. Equipped with Supply Authority Current Transformers Rated at 200A, 6 Power and Lighting split chassis all with private whole current metering. Also included was a 100A Contactor style change over switch for Essential Lighting and Power Chassis, both supplies protected by 2 separate 40KA surge diverters. This design took into consideration of the tight space we had to fit the Distribution Boards whilst still maintaining a sustainable energy solution to Symantec’s offices.

Early May 2014 the manufacturing process of the Distribution Boards was actioned. Early the next month the boards were tested with our Inspection and Test Plan procedure (ITP). After passing the ITP they were then delivered in sections to the Symantec building in Kent St. Later that week Southern Cross Switchboards assisted Stowe Australia to join the sectioned Db’s and position them into the tight spaces that they were designated for. Over two days Southern Cross Switchboards went to site to electrically and mechanically connect the sectioned Db’s and then conduct another ITP to conclude the project.

Value : 97k

Darling Harbour Live Temporary MSB

After 25 years of operation, the Sydney Convention and Exhibition Centre Darling harbour closed in January 2014 to make way for the development of the new $1 billion event and exhibition facilities, due for completion in 2016.

A Stowe/Fredon join venture were awarded the $80 million project to undertake the electrical services installation. This included the design, supply, delivery and installation as part of the redevelopment of the site.

In June 2014 Southern Cross Switchboards were awarded the project of supplying and rework of two 1600A Main Switchboards with a quick turnaround of 12 days.

The project consisted of removing the existing MSB’s and have them shipped to our workshop in Silverwater. Once the boards were in the work shop we stripped the boards of all existing switchgear and components. We then re-designed the switchboard whilst maintaining the existing frame. Both boards required a 1600A Service Protection Device along with Supply Authority Current Transformers. The existing MSB2 was too small so we had to manufacture and join a new tier to allow for the supply authority section, which then fed a number of breakers ranging from 800A to 100A MCCBS. There were outdated chassis on the board that we had to source breakers to suit. Both Boards were roughly 3m long and stood 2.3m tall. We managed to utilise some of the existing busbar. However in some sections we had to completely re design the arrangement.

Once the boards were complete we then carried out our Inspection and Test Plan (ITP). We the transported the switchboards to Darling Harbour to Fredon/Stowe. Total duration of this project was 12 days ” Phew “.

Value $20k

German Consulate – Sydney

In September 2015, the Consulate-General of the Federal Republic of Germany in Sydney relocated from 13 Trelawney Street, Woollahra NSW 2025 to Level 17, 100 William Street, Sydney (Woolloomooloo) NSW 2011. 100 William Street is an instantly recognizable Sydney landmark. The office building is located close to all major transport routes, with a choice of railway stations including St James, Museum and Kings Cross and all major buses, it is easily accessible via all modes of transports.

Southern Cross Switchboards won the tender to supply two distribution boards for the German Consulate at their new location at 100 William Street. They were DB-R30 (AV) and DBG-R30 (SV), IP42 rated switchboard with fault level 6kA for 1 second. The distribution boards were required to be painted White. Unlike other common distribution boards which comprise of single pole and/or 3 pole breakers, these distribution boards actually comprise of 2 pole and 4 pole breakers.

DB-R30 (AV) is rated at 80A. The distribution board has an 80A 4P main switch, a surge diverter, 5 x power meters, 4 x 4P outgoing breakers (3 for power sections and 1 for lighting section), 63 x RCBOs, 2 x RCDs and 3 x MCBs. DBG-R30 (SV) is rated at 63A. It has an 80A 4P main switch wound down to 63A, a surge diverter, 4 x power meters, 3 x 4P outgoing breakers (1 for power section, 1 for lighting section and 1 for server/telecommunication section), 16 x RCBOs and 2 x MCBs.

Value: $58k

2 Market Street DB

Located at 2 Market Street, Sydney is Allianz Centre, a 24 level high rise commercial office building with an adjoining seven level forecourt building. The building currently comprises 39,818 square meters of office space, multi-level basement car parks, food court and retail area. The multi-level basement car parks have the capacity to house over 300 vehicles. The building was completed in 1990 and redeveloped in 2007.

The redevelopment was carried out in four phases:

Phase 1 – Office Tower

Demolition of the existing two low rise buildings and associated structures fronting Kent Street
Provision of new structural columns and enhancing a number of existing columns to the basement car park
Construction of a new six storey commercial /retail building fronting Kent Street

Phase 2 – Market Street Frontage

Internal modifications to the existing foyer/colonnade to allow for the introduction of retail space
Alterations and upgrade of the façade and installation of awning along the street frontage

Phase 3 – Level 7 Food Court Modifications

Internal modifications including removal of existing food court and the introduction of open plan retail space
Alterations and upgrade of existing Sussex Street frontage

Phase 4 – Enclosure of Sussex Street Colonnade

Infilling of existing colonnade to allow for the introduction of retail uses
Alterations and upgrade of the existing podium façade

Southern Cross Switchboards supplied a 800A distribution board as a temporary power supply for 2 Market Street project in Sydney. The distribution board is a IP42, Form 3bih with a rated fault level of 25kA for 1 second. It was a simple distribution board with an 800A main switch for the incoming supply and 4 x 250A circuit breakers for outgoing loads.

Value: $11k

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