A major Victorian steel processing facility required a staged electrical upgrade across a continuous coating line, including new control panels, cable tray, field wiring, safety devices, hazardous area equipment and commissioning support.
The project involved a complex mix of installation and support works across production areas, coater rooms, control panels, hydraulic and pneumatic systems, MCC infrastructure, field devices and operator stations.
The works were delivered around an operating industrial environment, with staged access, permit requirements, shutdown windows, commissioning support and follow-up modifications required as the upgraded equipment was progressively brought into service.
Project snapshot
- Major industrial steel processing facility in Victoria
- Electrical upgrade works across a continuous coating line
- Installation and modification of cable tray, conduit and field cabling
- Control cabinet, MCC, remote I/O and servo panel installation support
- Prime and finish coater room electrical works
- Control stop, operator panel, hydraulic and pneumatic panel modifications
- Hazardous area cabling, Ex-rated glands, barrier glands and labelling support
- Profinet, Cat6A, fibre and industrial communications cabling
- Safety device works including E-stops, limit switches, fortress locks, tower lights and solenoids
- Commissioning support, fault finding and follow-up rectification works
The challenge
The project required electrical installation works to be completed inside a live industrial production environment with strict access, safety and permit requirements. The work area included existing equipment, hazardous area considerations, operational constraints, control panels, cable trenches, elevated work areas and multiple contractor interfaces.
The electrical upgrade was not a simple new installation. It involved integrating new equipment and controls into an existing production line, removing redundant infrastructure, modifying cable tray and conduits, installing new control panels, wiring field devices, and supporting commissioning activities as the upgraded systems were tested and brought online.
The works also needed to account for inspection requirements, hazardous area equipment, intrinsically safe circuits, panel modifications, production timing, access to MCC areas and the practical realities of completing industrial installation works around an operating site.
The approach
The works were completed in stages, beginning with site review, training, access requirements, cable route checks, material deliveries and installation planning. Early activities included measuring cable tray and cable runs, confirming routes, installing unistrut supports, installing tray, modifying tray sections and preparing the site for larger installation works.
As the project progressed, works moved into control panel installation, MCC cabling, field wiring, cabinet positioning, cable terminations, conduit installation, cable trench works, remote I/O panel works and modification of existing control infrastructure.
During commissioning and follow-up works, the focus shifted to practical site support: testing devices, modifying wiring, assisting with hydraulic and pneumatic panels, replacing faulty components, installing labels, assisting with hazardous area requirements and supporting the site as equipment was progressively brought back into operation.
Electrical installation works involved
The electrical installation scope covered both new infrastructure and modifications to existing plant equipment.
- Installation of 450 mm and 600 mm cable tray sections
- Installation of tray dividers, tray lids, unistrut supports and mounting hardware
- Installation and modification of steel conduit around production areas
- Pulling, securing, glanding and terminating multicore and control cabling
- Cable trench preparation, floor plate access and cable routing through MCC areas
- Installation of new cabling between coater rooms, control panels and field devices
- Removal of redundant cables, conduits, sensors and old control equipment
- Installation of temporary power and fibre cabling for testing and commissioning support
- Power, data and industrial communications cabling
- Labelling, testing, fit-off and practical handover support
Control panels, MCC and field devices
The project required installation and modification support across multiple control and field systems. This included work in MCC areas, process control boards, operator panels, remote I/O panels, servo panels, hydraulic panels, pneumatic panels and temperature control panels.
- Control cabinet and remote panel installation support
- MCC cable installation, glanding, termination and labelling
- Remote I/O and temperature panel wiring
- Servo drive cabinet installation and support
- Hydraulic and pneumatic panel wiring modifications
- Operator panel wiring and pushbutton modifications
- Control stop circuit modifications
- Sensor, proximity switch and field device wiring
- Junction box installation and field termination works
- Industrial communication cabling including Profinet, Cat6A and fibre-related works
Hazardous area and safety-related works
Parts of the project involved hazardous area considerations and safety-related device installation. These works required careful planning around equipment location, cable routes, gland selection, labelling, inspection requirements and site procedures.
The works included installation and modification of Ex-rated and hazardous area-related components, barrier glands, intrinsically safe cabling, simple apparatus labels, stainless labels, junction boxes, tower lights, E-stops, limit switches, fortress locks, solenoids and related wiring.
Safety-related work was carried out as part of the broader electrical installation and commissioning support package, with device installation, wiring changes, testing support and follow-up modifications completed as site requirements were confirmed.
Commissioning and production support
As the upgraded systems were brought into service, commissioning support became a significant part of the project. This included assisting with device testing, panel checks, wiring modifications, fault finding, control panel changes and follow-up support as issues were identified during testing and production readiness activities.
Support was provided across hydraulic panels, bridle panels, servo motors, tower lights, operator panels, water treatment equipment, temperature devices, density meters, solenoids, field cabling and safety devices.
This type of support is critical on industrial upgrade projects because not every issue is visible during the installation stage. Once the equipment is tested in context, practical electrical support is often needed to resolve faults, complete modifications and help the site progress through commissioning.
Redundant equipment and enabling works
The broader works also included enabling activities to support the upgrade, including redundant cable removal, old panel and switchboard removal support, temporary wiring, fibre installation and preparation works in other site areas to support testing and system readiness.
These enabling works helped clear redundant infrastructure, prepare temporary supplies, support staged testing and provide the site with the cabling and access required for commissioning activities.
The outcome
The completed works supported a major upgrade to the site’s coater line electrical and control infrastructure. New cable tray, cabling, control panels, field devices, hazardous area components, safety devices and commissioning support helped move the upgraded systems toward operation.
The project demonstrates the importance of practical industrial electrical support on complex brownfield upgrades. The work required more than installation labour; it required coordination, problem solving, safe work planning, site familiarity, control panel understanding, commissioning support and the ability to respond as requirements changed during the project.
For industrial customers, this type of project highlights the value of having electrical support that can work across installation, controls, field wiring, hazardous area requirements, commissioning and ongoing production support.
Industrial works demonstrated
- Industrial electrical project works
- Control cabinet and MCC installation support
- Industrial cable tray, conduit and field wiring
- Remote I/O, servo, hydraulic and pneumatic panel support
- Hazardous area electrical installation support
- Safety device installation and wiring modifications
- Commissioning, testing and fault-finding support
- Redundant cable and equipment removal
- Shutdown and staged installation support
- Follow-up rectification and production support