Project Overview
Project Type: Mine Site Power Distribution Network Upgrade & Expansion
Completion Date: September 2024
Location: Pilbara Region, Western Australia
End Client: Major Iron Ore Mining Company
Local Switchboard Builder: TSTYNICE Certified Australian Partner
Application: Providing reliable power distribution for a new ore processing plant and camp facilities, replacing aged diesel generation.
Technical Solution
In collaboration with a local switchboard builder, TSTYNICE delivered a complete 11kV Medium Voltage to 1kV Low Voltage mining-grade power distribution solution, comprising an oil-immersed transformer and AS/NZS-compliant outdoor switchboards.
Supply Scope
1. Main Power Transformer
Model: MIN-S11-M-2000/11
Capacity: 2000 kVA
Voltage: 11 kV ± 2x2.5% / 1050 V (1.05 kV)
Frequency: 50 Hz
Type: Outdoor, oil-immersed, mineral oil insulation, ONAN cooling
Special Design: Mining-duty ruggedized, Dyn11 vector group, reinforced mechanical structure for high-vibration environments.
Standards: Compliant with AS 60076.1 and AS 2374.1.
2. 1000V (Ue) Rated Outdoor Main Switchboard (OMSB)
Ratings: Ue = 1000V AC, Ui = 1100V, Icw = 65kA/1s
Incoming Supply: 1 feeder from transformer LV side, fitted with a 3200A Air Circuit Breaker (ACB) with microprocessor protection.
Outgoing Feeders: 12 circuits including:
4 x 630A (Crushers, Conveyor Motors)
4 x 400A (Water Pumps, Compressors)
4 x 250A (Lighting, Camp, Auxiliary Power)
Enclosure: Fully welded steel construction, IP54 protection rating (dust and water jet protected), C5-M corrosion protection finish (sandblasting + epoxy zinc-rich primer + polyurethane topcoat) for coastal high-salinity environment.
Internal Construction: Compliant with AS/NZS 61439.1 & .2, Form 4b, Separation Type 4.
Busbars: Copper, rated 4000A, short-time withstand current 65kA.
3. Outdoor Capacitor Compensation Panel
Capacity: 600 kvar, Automatic Power Factor Correction (APFC)
Design: Detuned configuration (7% reactance) to suppress 5th and 7th harmonics from Variable Frequency Drives (VFDs).
Core Features
1. Extreme Environment Adaptability
Climate: Designed for ambient temperatures up to 50°C, with all components derated to ensure full-load capability.
Protection: Switchboard doors feature dust-proof seals and anti-condensation heaters. Transformer tank has special coating for UV and corrosive red dust resistance.
Structure: All external fasteners are stainless steel. Switchboard base is raised 200mm to prevent floodwater and dust accumulation.
2. Safety & Reliability
Safety Standards: Fully compliant with Australian AS/NZS 3000 (Wiring Rules) and mine site electrical safety regulations.
Operational Safety: Switchboard features mechanical interlocking, lock-out provisions, and viewing windows. Transformer equipped with pressure relief valve, sudden pressure relay, and oil temperature monitoring.
Maintenance Ease: Modular design. Transformer has tap changer and online oil filtration interface. Switchboard utilizes withdrawable circuit breakers for easy maintenance.
3. Local Integration & Compliance
Collaboration with Local Builder: TSTYNICE supplied the transformer, core switchgear components, and complete design drawings. Final assembly, wiring, and local certification were performed by the certified Australian switchboard builder.
Certification & Testing: Full type testing completed before shipment, including transformer temperature-rise and short-circuit withstand tests, and switchboard temperature-rise, dielectric, and short-circuit strength verification. Test reports compliant with Australian requirements were provided.
Project Execution
Collaboration Model: TSTYNICE (Design, Core Equipment) + Australian Local Switchboard Builder (Assembly, Local Compliance, Installation Support).
Delivery Timeline: 18 weeks total (4 weeks design finalization, 12 weeks manufacturing, 2 weeks sea freight).
Site Installation: Completed by the client's electrical team under the technical guidance of the local builder, significantly reducing costs.
Commissioning: Jointly conducted by engineers from both parties, including protection relay setting, APFC logic testing, and full-load trial operation.
Operational Results
Reliable Power Supply: The system has operated fault-free for over 6 months, successfully replacing high-cost diesel generation and providing stable power to the processing plant.
Energy Efficiency: Power factor consistently maintained above 0.98, avoiding utility penalties and reducing line losses.
Reduced Maintenance: The rugged design has minimized routine maintenance requirements in the harsh environment.
