2030Smart Boards

Coffs Harbour 2030Coffs Harbour City Council

2030 Smart Boards

Design/Tender discussions with Andrew Sales & Andrew Gray

6+ years of getting the design right by finally closing the loop!

IPWEA Award Winning

We operateand maintain

Design

Feedback

Introduction• Product range

– Series 1– Series 2 (Type1, Type2, Type3)

• The flawed process– The tender process

• An effective design– Product design

• The benefits– Capital cost savings– Operating cost/time savings

Product Range (Pump Stations)

• Series 1 (Generation 3)– 1kw to 15kw

• High quality 316 S.S Cabinets

• Integrated soft starters• Half I/O Enet• Integrated stand• Rear mounted CE• Generator changeover• Compact Design• Antenna mounting

Product Range (Pump Stations)

• Series 2 Type 1 (Generation 3)

– 15 to 22kw (45kw Single pump run)• High quality 316 S.S Cabinets• All in one design• VSD design• Integrated CE board• Externally Cooled

• Series 2 (Type 2) (Generation 3)

– 22KW to 75KW• High quality 316 S.S Cabinets• High quality CB chassis• VSD design• Separate CT metering• Up to 630 Amps• Externally Cooled

Product Range (Pump Stations)

• Series 2 Type 3 (Generation 3)– 90KW to 160KW

• High quality 316 S.S Cabinets• High quality MCCB Chassis• VSD design• Separate CT metering• Up to 630 Amps

Product Range (Pump Stations)

Civil Spec

Elect Spec

Elect Contractor

20% mark up20% mark up

Pay 87% morePay 87% more

The Flawed Process

Low Qty price 20% more20% more

Design Tender

Tender

Review Tender

Award Tender

Civil Contractor

Generation 0 switchboard

One off design

30% mark up30% mark up

Project Goals• Relationship to other projects• Ultimate goal of project• High-level timing goals

EFFECTIVE

DESIGNSAVES

$

MultiAlarmingSystem

AntiVandalism

System

SystemCompliance

FutureProofing

LightningProtection

System

StandardSystems

BackupPower

Systems

VerminControlSystem

CoolingControlSystem

Vermin Control System 2 stage system

• Stage 1– Vents are Termimesh Stainless Steel 316

Mesh• Ant Proof• Will not rust• Easily cleaned

• Stage 2 – Entry & Exits are cable glands only– Conduit sealing systems in cable zone

Keeping vermin out = Longer life

VerminControlSystem

Cooling Control System

• Low maintenance cooling systems• Series 1

– Ceramic fans (No bearings)– Very Long Fan life– Thermostatic controlled (Constant Temperature)– Low power consumption so run on batteries– Cooling calcs have been carried out

• Series 2– Entry & Exits are cable glands only– Rear external venting of VSD– No heat in the box all external– Thermostatic controlled fan internal & external– Cooling calcs have been carried out– Also have requirement for heating if required in cold

environments

Constant cooler temperature = Longer life

CoolingControlSystem

Multi Alarming System

• Local alarming have provided a strobe with a near vandal proof cover which we have developed in house

• Local relay based control system for backup

critical well and simple control system

• Log Faults last 5-10 faults locally

MultiAlarmingSystem

Anti Vandalism System

• Robust locking systems– 316 handle that takes standard padlocks– 3 point locking system for door

• Provide specialised light cover design– Vandal proof light cover

• Solid 316 stainless steel construction

• Since we use standard boxes easy to replace if it gets smashed or damaged.

AntiVandalism

System

Backup Power Systems

• Backup Generator Sockets 4 Pole change over switches

– Designed are per regulations– DS3 & DS9 Marechal inlets and lockable covers – Lockable Gen-set inlet covers

• Backup Batteries system– 12 /24 Volt battery backup– Batteries correctly charged and discharged and

floated correctly

Good battery management = Longer battery life

BackupPower

Systems

System Compliance

• AS/NZS 3000:2007– Thermistor protection – Full load isolation switches– 4 pole Gen-set changeover switch– Interlocking Door Panels– Earth leakage detection G.P.O’s

• Local service and installation rules• OH&S (Work cover safe working)

– Isolatable switch board– Viewing Windows– Easy to operate– Standard procedures– Standard training– Standard manuals

SystemCompliance

Future Proofing

• MAS 711 support for ITT Flygt pumps over 70kw capacity

• ITT Flygt support for the MiniCas II relays

• Handheld plug in laptop with full mimics etc

• Product improvement working constantly with vendors to improve the product. When you have a standard, vendors are more likely to take feedback

• Main Vendors– B & R Cabinets– Serck Controls– Schneider Electrics

FutureProofing

Lightning Protection System3 Level system• Stage 1

– 3 Phase primary parallel lightning protection• Protect VSD’s etc

• Stage 2– 1 Phase mains to control system

• Control system protection• Radio• Telemetry controller• Other control devices

• Stage 3– All 4 – 20mA inputs protected– All Digital I/O via a relay– Plus radio lightning protectionEffective lightning protection = Longer

life

LightningProtection

System

Standard Systems

• Standard Parts we have standardise on a set of parts for ease of sparing

• Standard Drawings provide comprehensive easy to read drawings

• Standard Boxes we use standard B&R so easy to modify and get quantity quickly also to carry out upgrades

• Standard Testing is carried out on all units using a automated SCX test system

• Standard Operating procedures• Standard Manuals improve the quality of manuals• Standard Training

Standard systems = Save Money

StandardSystems

Generation Issues Resolved

• DC breakers (No fuses)• Front panel switch and alignment integration• Correct battery charging• Labels (all screwed on)• Phase failure relay• All in one motor control

(thermal/magnetic/contactor)• etc

• Capital Costs– Electrical pump station costs decreased– No tender or tender specification required– No electrical design required any more for tender – Much lower install costs– Able to sell to developers with profit– You get what you want– Generation 3 board provided not a Generation 0

The BenefitsEFFECTIVEDESIGNSAVES

$

The Benefits

• Operating Costs/Time– Increased life = Decreased whole of life costs– Reduced visit to pump stations– Reduced overflows (EPA fines)– Lighting Protection = Overflow reduction– Spares & time to repair, quicker response times– More knowledge of each site for operators– Training and documentation is much better

EFFECTIVEDESIGNSAVES

$

• Award winning switchboards (IPWEA)• We have built our systems on whole of life costs

(Operating efficiencies) not built for a price. • Tender= Built for a price• We have already done the hard work of tendering and

vendor selection. The best product for the best price.• Full range covered (1.1kw to 160kw) VSD

(1.1kw to 15kw) DOL / Soft starter• Available of the shelf (3-6 weeks delivery)• Longer Life • Local Government ACT 1993 (Part 3)

Clause 55 “What are the requirements for tendering?”(3) This section does not apply to the following contracts: “a contract entered into by a council with another council”

• We now have Generation 3 boards not Generation 0

Our Unique Position

Questions

?Thank You