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Project Scope

Rio Tinto required upgrading and expanding of their permanent camp facilities at Rocklea and Tom Price resulting in the need to upgrade the 11kV distribution networks. The scope of works included:
 

  • Paraburdoo (Rocklea Palms) Battery Limits:
    • Three 11kV / 433V 1-2MVA transformer kiosks with integrated 11kV RMU and LV switchgear
  • Tom Price (Windawarri) Battery Limits:
    • Four 11kV / 433V 1MVA transformer kiosks with integrated 11kV RMU and LV switchgear

Kiosk substation manufacturing to conform to Rio Tinto specifications, including but not limited to:
 

  • 11kV / 433V transformer sized to suit the LV electrical loadings provided by third party
  • Separate compartments for HV, transformer, LV and Remote Operation Panel (ROP)
  • Full oil containment bunding, enclosed and separated from rain and the outside environment
  • Naturally ventilation to dissipate heat and minimise dust and other contaminants

Challenges Overcome

  • Limited documentation available on the existing HV network and kiosk substations due to age of equipment. The documentation that was available was typically outdated.
  • Limited historical data and no real-time site load data to verify asset utilisation and spare capacity.
  • Scheduling site visits and site soil resistivity testing during COVID-19 lockdowns.
  • Difficulty identifying suitable locations for new equipment around existing underground services.
  • Cutting over and jointing to existing underground cables of varying types or overhead line tie-ins.
  • Establishing SCADA and communications for the kiosks that had previously not been connected to the network manager.

Solution

  • Site visits with local stakeholders to identify constructability issues and define cut over methodologies to ensure continuity of supply.
  • Kiosk locations selected to minimise footprint and length/size of HV/LV cabling to aid council approvals.
  • Assessment to reduce the fire separation zone of outdoor transformers to adjacent buildings and infrastructure through additional instrumentation and analysis to reduce protection clearance times.
  • Updating and performing power systems modelling using DIgSILENT PowerFactory including arc flash.
  • Assessing the suitability and rectification work required to spare kiosks to reduce capital costs.
  • Complete earthing system modelling with CDEGS using site data.
  • SCADA and communications technical design and interface into network manager.

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