This project involved the replacement and upgrade of two existing Main Switch Boards at separate locations at the University of Sydney Camperdown campus. The works also included extensive refurbishment of heritage buildings and Fire Services.

Both construction sites provided challenges with the isolation of supplies feeding sensitive buildings and equipment. As such, detailed site surveys of an aged electrical system were conducted to create a staged migration plan outlining numerous out-of-hour outages and cutovers. The electrical surveys also provided power readings to calculate temporary power requirements for the end supply to each of the campus’s buildings. The migration plans, cutover strategies and temporary power requirements were presented to the Universities many stakeholders over numerous presentations to ensure clear communication and understanding of the philosophy, timing and impact of our works. 

It was a credit to the construction team that all cutovers were successfully completed to the original program with zero down time to the Universities many buildings and zero incidents which delighted the anxious Academics. 

HOLME BUILDING MSB REPLACEMENT

• The amalgamation of two existing 600A & 400A supply feeds from separate substations into one 1000A new MSB to replace the obsolete Holme Main Switchboard. Installation and cutover of three distribution boards over a one week out-of-hour cutover.
• Installation of an outdoor Mobile Generator Change Over Cubicle.
•  Excavation of a busy footpath for the installation of new 12 x 1c x 300mm² Fire Rated Consumer Mains.
•  Four mobile generators supplying temporary power to campus buildings over a two week cutover period. Buildings included the Universities PABX, lecture theater’s and Biological buildings with numerous ongoing experiments and life support systems operating for various animals.
• The Holme Main Switchroom underwent building works to demolish the internal dividing wall creating room for the New MSB and electrical service.
•  Installation of 197 GPO’s within the Footbridge Theatre supplying power for student laptops.

 SUBSTATION  54 REPLACEMENTS

• This project replaced an obsolete Main Switchboard a new 1600A MSB.
• The works included providing six mobile generators to locally power campus buildings for the one week duration of the staged MSB cutover and coordinating re-fueling of the generators. Buildings included the Universities PABX, lecture theatres and Biological buildings with numerous ongoing experiments and life support systems operating for various animals.
• Installation of new 12 x 1c x 240mm² consumer mains from new Pad Mount Sub Station.
• Multiple staged cutovers which included jointing and redirecting existing SWA submains.
• The Old Sub building and Old Switch Room underwent extensive repair and restoration works in line with heritage listed buildings.
• New Fire Protection installation works to Switch Rooms.

Value $995k

As part of this new Solar Facility Centre construction, Ryan Wilks’ conducted the power distribution and process control installation of the specialised industrial process plant & equipment together with all mechanical control, cooling water VSD control and air ventilation requirements within the plant rooms.

This new installation included all cable support design & installation, supply of numerous Distribution Boards, together with all submain / final circuit reticulation and control cabling from Local Control Panels to specialised process equipment in the field including, air compressor systems, fume exhaust systems, abatement’s systems, acid scrubbers & gas cabinets. 

This project was successfully completed, on time, within budget on the back of an exceptional safety performance record.

The Department Of Education & Training (DET) had released a much awaited electrical Upgrade Project at this northern beaches school. The works included various components including: 

• New Power Monitor & Surge Diverter Installation to the incoming consumer mains at the Main Switch Board.
• Replacement of over 330 Circuit Breakers with new RCBO’s within the Schools Distribution Boards in line with Australian Standards.
• Installation of 99 new general power outlets throughout the school.
• Installation of 32 new data  outlets throughout the school.
• Installation of timers to all security and walk way lighting throughout the school.
• Various lighting installation and electrical repairs works. 

Due to project time constraints and the schools busy time table the above works were completed in only a two week holiday period. In this time frame a high percentage of tripping RCD circuits were also rectified with a substantial amount of additional works requested by the school. High praise was received from the school for Ryan Wilks planning and clear communication strategies.

Ryan Wilks was engaged by a leading Building Management System provider to carry out  power monitoring installation works as part of a new BMS Power Monitoring Upgrade with this major facility.

A total of 67 Power Meters were installed combining upgrades of existing aged analogue power metering with PM710 together with Modbus Energy Meters at the facility’s Main Switch Boards, Generator Main Switch Boards, Rectifier Main Distribution Boards, Mechanical Main Distribution Boards & Light & Power Distribution Boards. All Modbus cabling was run to newly installed break out box’s mounted at the top of each board ready for BMS connection.

The main challenge with this particular project was to ensure a seamless transfer of supplies to the critical supplies in the facility. All installation works and isolation’s were conducted out-of-hours on a level-by-level basis to minimize the impact of any potential down time to data equipment. Our experienced team ensured there was no compromise to safety or integrity of delicate communication equipment by conducting vigorous onsite investigations, planning extensively and creating comprehensive contingency strategies within detail work procedures.

This project was delivered ahead of schedule even with numerous unforeseen faults and control issues being addressed. The success of this project again proves Ryan Wilks has the experience to deliver complicated high level electrical projects within the telecommunication sector.

• Temporary mobile generator configured to start automatically, supporting the facility on mains power failure & for the duration of the project.
• Underground Bulk Fuel Tank Integrity Testing.
• Demolition of existing SGP, remote radiator all associated SGP equipment.
• Demolition of internal existing Generator room internal wall to create a larger Plant room Via new concrete filled block wall encroaching on the neighboring Battery Room.
• Extensive dust protection solutions.
• New Air intake & exhaust air attenuation complete with intake and exhaust air fans.
• Remote Air Radiator & cooling water pipe work to upper level car park.
• New diesel exhaust muffler.
• New Generator MSB.
• New 4 x 1c x 500mm² Fire rated Generator Mains and associated Generator control cabling.
• MSB ATS Logic control modifications.
• New Generator Auxiliary DB complete with air attenuation & radiator fan control.
• Acoustic wall lining.
• Battery Room Air Ventilation, complete with Vermiculite Fire Rating, Fire Dampers & electrical fan supplies.
• New BMS alarm points.
• Generator pre-start checks,  dummy load testing & building load commissioning.
• New Generator room & battery Room Lighting.
• Epoxy floor finish.
• External Bollards to protect Generator air attenuation.

This project required substantial input in the attenuation design to meet acoustic standards at the residential boundary together with height limitations within the generator room impacting on duct work layout. Ryan Wilks worked closely with the consulting engineers to achieve the best solution to a number of engineering challenges.

This small facility underwent a Ryan Wilks special and quick-fire Standby Diesel Generator Upgrade to the usual high quality standard expected by our client. The project team completed the works in no more than 4 weeks, maintaining building emergency power via temporary generator arrangements and completing the works with zero incidents and no impact to the day to day operations of the exchange.

The existing 65kVA SGP was upgraded with a 113kVA SGP together with new inlet and discharge air attenuation, diesel fuel lines, new exhaust system through 3 levels of the facility, MSB control alterations, acoustic testing, diesel bulk tank integrity testing, stringent generator commissioning & plant room refurbishment.

The project was completed well within time constraints and would have been bettered if it were not for the difficult tenants who were eventually evicted by the local bee exterminator.

Delta Electricity currently used a hydrant hose reel type pipe work system to daily wash down the coal supply system.  To reduce costs associated with this water cleaning Delta proposed to install an alternate, more cost effective coal wash down pipe work system using the local river supply. In addition it was proposed that this same pipe system could, in the future be also used as a vacuum pipe system. The project brief involved the supply of labour and expertise to develop the initial Delta concept design (sketch) for the new wash-down system into a fully commissioned and operational system incorporating the installation of  free issued pipe work and fittings (threaded black steel pipe work, hose reels, valves unions and fittings) supplied by Delta Electricity to cover the approx 750 m length of the Conveyors 1, 2 & 3 and the transfer towers. 

Following an inspection on site  Ryan Wilks observed a number of significant design and OHS issues that would need to be resolved before any works could start on site. In addition to obvious issues such as working within an operational power station and the strict OHS & E policy’s and procedures in place some of the specific factors that we had to consider in our design development were;

• Working around and above operating conveyors
• The coal, and more importantly coal dust
• The length of, and accessibility to each conveyor section, (overall length of approx 750 m)
• The slope (rise) of each conveyor, slopes up to 1:4 in Conveyors 2 & 3 (overall vertical rise approx 80m)
• The installation of threaded pipe & fitting
• Thermal Pipe Expansion (and contraction) of the pipe work due to temperature variants
• Thermal System (Water) Expansion due to temperature variants
• ERW (black steel) Pipe work
• Sealing of threaded pipe Joints, and or disconnection of “lock-tite” sealed joints for maintenance.
• Screwed connections, a major safety concern regarding the installation
• Use as a  Vacuum system 

In consideration of the above risks Ryan Wilks submitted two tenders for this project, one a complying bid based on the use of the existing free issue fitting and a second tender based on an alternate design based on the use of rolled groove or  Victaulic galvanized pipe work and fittings. Our alternate design proposal (our engineered solution) generated a lot of discussions with Delta Electricity and proved to be the winning edge in securing this project for Ryan Wilks. By using the rolled groove Victaulic pipe work system Ryan Wilks were able to:

• Overcome a number of installation and design concerns noted above
• Reduce installation time. The victualic joints are quicker and easier to install as each joint required only 2 nuts to be tightened up on the coupling joint, thus eliminating the use of large stillsons and risks associated with tightening (screwed) joints adjacent to the operating conveyors.
• Reduce OHS risks associated with the works
• Reduce potential leaks associated with threaded connections
• Allows any pipe section to be easily removed, replaced for serviceability
• Victaulic Flushseal gaskets are rated to 99.9% vacuum
• Use of galvanized pipe and fittings, negates painting and minimizes (eliminate) rust problems as opposed to use black steel pipe
• Re-use existing pre-purchased (free issue) valves, hose reels and pump
• & most importantly provided a costs savings to Delta Electricity 

The rolled groove Victaulic joints provided the airtight seal required, allowed easy installation, and more importantly easy removal if required for individual pipe sections. It proved a win win scenario for both Delta Electricity and Ryan Wilks. 

So what did we actually do on site. Water was taken from the existing creek supply and run 200m in plastic pipe to the  new 200,000 litre washdown storage tank installed by Delta. From the tank the water is then pumped to the new main washdown pipe that runs the full length of the conveyors. The pipe runs from the bottom at the start of Conveyor 1 up to the top located at the end of Conveyor 3, a total length of in excess of 750 m and rises vertically 80 m. Along the main pipe run a total of  21 hose reels and 32 vacuum ports have been installed.  To minimise the likelihood of pipework connections becoming blocked when the system is used in vacuum mode each connection was made into the side of the main pipe. In addition isolation valves were fitted to enable each conveyor section of to be isolated for use in vacuum system, or for maintenance purposes. Nothing on site was done small. The new pump required a new supply cable to be run from the main switchboard then along Conveyor 1,  under an access road to the pump, a total length of 300 metres. 

The project was a success for both Ryan Wilks and Delta Electricity and was delivered on time and under budget.

The National Archives site provides storage of permanent Commonwealth records of enduring value and in many instances the stored records are irreplaceable. The Chester Hill site contains approximately 90% of the audio-visual records and 40% of the paper records held by the National Archives of Australia. The conditions within the building must be strictly controlled and monitored to maintain the life of the records stored within each area.

Originally the security vault and low temperature film vault were being served (dehumidified) from common desiccant units serving the film vault and inter-connecting duct and dampers.

Due to lowering of temperature within the film vault this meant that a new stand alone desiccant dehumidifier had to be installed to serve the security vault. As the two existing (duty/stand by) Munters desiccant units that serve the film vault had reached end of life these two units were to be replaced as part of the upgrade.

Whilst the change over of the two existing low temperature film vaults was relatively quite simple the work had to be planned and staged so that the conditions within the room ( 9^oC +/- 1^OC and 30%RH +/- 2% RH) were maintained at all times. The work, disconnect, replace, re-connect commission had to be completed in two four hour windows and involved fours separate trades.

As part of our tender submission Ryan Wilks in addition to offering a complying tender submission for the new Security Vault unit Ryan Wilks offered for consideration the supply of Seibu – Giken desiccant unit. We are please to say that National Archives advised that Ryan Wilks were the only tender submission to offer an alternate option and that this innovation went a long way to securing the prestigious project.  Our alternate unit enabled the National Archives to integrate a new supplier into their system on a small scale for evaluation and to open up the marketplace and stop any monopolisation by any one supplier.

The Security vault involved the supply, install and commissioning of one new desiccant dehumidification unit to maintain conditions within the space of 20^oC +/- 2^OC and 50%RH +/- 5% RH). The works involved minor new ductwork to be cut into the existing security vault return air, new circuit breaker to be fitted to existing switchboards and connecting and commissioning of new BMS connects to the base building system. The works were “roughed in” in readiness for single cut over which was completed with the four hour shutdown window.

This project was another example of Ryan Wilks innovation by offering our clients an alternate option, completing critical cut over’s within tight time restraints and completing the works on time, on budget and to the satisfaction of our client.

Whilst the air conditioning ductwork modifications may have appeared simple and straight forward and similar to recently completed works at a Nowra facility these works involved the completion of previously half complete works, and as the final works impacted on the airflows within the existing facility the works involved a large engineering and commissioning input.

Prior to commencing any works on site Ryan Wilks undertook a full commissioning check of the ground floor air conditioning system which served the existing equipment area and the new H3 area. This included full air balance, temperature readings, equipment tech data and readings and indirectly picked up a number of service/maintenance issues that were passed onto the client for rectifications (bearing issues, loose belts, excess outside air resulting in salt spray egress and build up). 

Following the ductwork modifications within the H3 area and the installation of Hot Aisle and Cold Aisle outlets the existing ground floor air conditioning system had to be re-balanced. The new area has resulted in a number of aisles within the equipment room now becoming redundant and existing equipment and load removed. This resulted in a number of existing outlets within the equipment area, and the ductwork branch dampers being closed off as to provide the new airflow to the H3 room.

The existing live equipment area and the H3 room were re-balanced as per airflow provided by the mechanical consultant. In addition temperature reading were taken through out the spaces and the final air figures adjusted to provide even temperatures with the facility and H3 areas. 

The existing air handling units and return air fan variable speed drives were re-set to suit new operating (static pressure) set points and the Innotech control logic updated to suit the final installation.

The existing as installed drawings were updated to reflect the modifications, and along with copies of new commissioning figures were issued to Transfield to be included within the existing site operating and maintenance manuals.

The were completed on time, on budget and to the satisfaction of our client.

The project involved the design, manufacture and delivery of custom made in-floor boxes to the suit SHFA requirements. This involved the design and development of a working prototype floor box, the physical testing of the prototype before approvals were given to manufacture the final units. 

The floor boxes were designed to be retro-fitted to the existing convention centre floor and were to house power (1ph & 3 ph) and data outlets to be used during exhibitions and displays. The boxes had a large lid for access purposes and small stainless steel cable entry flaps. 

 The installed boxes had to be flush fitting with the carpet so as not to present a trip hazard and strong enough to withstand 500 kg point loading from small scissor lifts passing over them. As such the boxes lid and frame section were fabricated from 10 mm mild steel plate powder coat finish. Due to the size and the weight of the main lid section gas strut supports were installed to assist with opening of the lids, and more importantly a safety device to stop the lids slamming shut. The lids were fitted with simple folded D handle which fitted within the carpet inlayed top for a flush finish.