EAF Dust Washing Facility

Case Study
Nyrstar Electrical Arc Furnace (EAF) Dust Washing Facility
Description
Status: Completed in 2011
Value: $2.4M (AUD)
Scope: Located on the Nyrstar Smelting Facility in Port Pirie South Australia, a new Electric Arc Furnace (EAF) Dust Washing Plant was required. The works involved; the demolition of existing facilities, civil works for a sump and pad, installation of precast walls, mechanical plant installation, construction and installation of a new Electrical Equipment Room (EER), electrical and instrument installations, and an upgrade to the LV and HV infrastructure in the existing substation.Construction ProvidedTotal Electrical Construction Pty Ltd was awarded Contracts for the Civil Works, Precast Walls Installation, Fabrication and Installation of the EER Room, Electrical and Instrument Installation and Substation Upgrade.Total Electrical Construction Pty Ltd provided 20,940 labour hours to complete the Contracts in just 11 months.

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The Civil Construction and Precast Walls Contract included the supply and installation of:
-Installation of precast sump (4.6m x 4.2m)-Installation of 132 Humes Precast Wall Sections
-Excavation and preparation of an area of 40m x 70m for the concrete pad
The Electrical and Instrumentation Construction Contract included the supply and installation of:
-Supply and installation of a new LV supply between the existing substation to the new EAF EER,
-An upgrade to the substation and associated HV and LV equipment,
-HV Switchboard extension (circuit breakers, PFC stringers and associated cabling) and tie in
-Demolition and installation of new 400V LV switchboard installationincluding modification of infrastructure
-Demolition, relocation of an existing GPO and cut over to a new sub board and circuits to new board
-Demolition and replacement with 1.5MVA 6.6/0.4kV Transformer-Air conditioning compressor relocation
-New power supply to booster fan VSD-LV cable, cable support, cable ladder and pipe rack
-Supply and installation of telephone cable and conduit between the substation and new EAF plant,
-Supply and installation of fibre optic cable, conduit and supports to the new EAF plant,
-Supply and installation of area panels
-New plant related works such as lighting, floodlights, CCTV, motor and field instrument installations (pressure transmitters, gauges, magnetic flow meters, ultrasonic level transmitter, conductivity transmitter, high and low level switches, flow switches, air regulators, solenoid valves), cable and control cabling, wiring terminations and cross patch wiring for all new plant equipment
-Trenching associated with new cable and conduit installation
-Testing
The EEr Construction Contract included:
-The supply of a 10m x 12m fabricated steel framed and clad transportable building with fire detection system, recirculation filtering pressurisation system and air conditioning
-Fit-out with a main switchboard/ MCC, PLC panels, communication and power equipment, cable racking, distribution boards, lighting, and VSDs
-Factory Acceptance Testing
-Stairs, access platforms, pipework cross over and footings
-Transportation, lifting and installation on site.