Project Description

• Construction of a new building, open cut tunnel and illumination of new tram tracks and surrounding public areas, including:
• Electrical, Communications, HVAC, Dry Fire, Security, Earthing and Bonding, Public Illumination, Metering, infrastructure and pathways, traffic signage, systems automation (PLC), lighting automation (DALI) and systems integration (SCADA).
• Tunnel:
  • All items installed in the tunnel are 3-hour fire rated to comply with Transport NSW
  • 6 Illuminated speed signs were mounted inside the tunnel and 2 non illuminated signs were installed. These signs had to meet strict font sizing, font styling and colour.
  • 5 x 4m long bi-directional project specific designed jet fans were mounted to the underside of the tunnel soffit to be used for emergency scenarios of fire and smoke.
  • Air Velocity Monitors were installed at both tunnel portals to monitor the direction and speed of air flow if there ever was an emergency within the tunnel and the jet fans needed to be used to assist with smoke flow.
  • A Linear Heat Detection fire detection fibre cable that is run in a continuous loop on the soffit from the substation along the down main track and then back via the upmain track into the substation. This system allows fast detection of any heat source and is an accurate measurement down to the metre along the 500m tunnel and can relay this information to the operation control command at Randwick stabling yard and the fire control room located within the substation.
  • The Jet fans can then be turned on remotely from the Operations and Control Centre (OCC) or locally in different directions to assist with the emergency situation via the PLC.
  • All metallic objects within the tunnel had to be electrically bonded using 70mm2 earth cable including each length of cable tray, jet fans, RTD and sump pump control panels, lighting and exits
  • The tunnel has a sump to discharge the water that collects from each portal. The pumps run and cycle automatically when the sump reaches a certain level all controlled by the PLC and if needed can be run from the OCC, manually from the substation or local controller inside the tunnel.
• Substation:
  • The substation proved to be difficult and rewarding with a maze of cable tray in the basement to support the 11KV switchgear and HESOP equipment above.
  • HESOP (reversible direct current electric substation) allows for recovery of 99% of breaking energy, reducing environmental impact and number of substations by 20%.
  • The Low Voltage Main Switchboard (TMSB)required with street closures and specialised rigging to place the 7.8m long switchboard into place.
  • Installation of the board had to be done after the building works of the substation were complete and we had already installed the raised flooring in the LV switchroom.
  • The raised flooring was used to allow cable reticulation from the TMSB to the MSSB, FIP, Fire pump package, Computer room and to the equipment room basement and out into the tunnel cable tray system. The TMSB is fed by 2 different supplies, the normal supply directly from the Ausgrid’s HV transformer and the backup supply from the Alstom private HV network.
  • The complex PLC programming was very complex, impacting the works from 6 different contractors, all relying on Kerfoot to provide them solutions to the integration of all the systems in the substation and tunnel.
  • The large HVAC system consisted of 4 x CRAC units 2.5m long by 2m high and 2 x 3 fan dry coolers which all had to be lifted onto purpose-built platforms by crane.
  • The HVAC system is design for “off-line” operations, going into action only when temperatures exceed the predetermined thresholds.

• Street Lighting:
  • This is a key area to ensure optimal illumination and maximum public safety to commuters, tram drivers and general public (pedestrians and drivers) in the vicinity of the light rail.
  • The optics for each luminaire were carefully designed and selected to ensure the light spreads in the correct direction and shape with specialised beam forming optics for minimum glare and optical safety.

 
Project Accolade

• Substation: The systems integration and automation mean that all installed services can be monitored and controlled from the Operations Control Centre allowing the building to be unmanned.
• Tunnel: spanning over 500m, with 180 light emergency and exit fittings it houses over 75 ton of steel, 65km of cable and over 50 ton of copper to integrate jet fans, lighting, hydraulic and essential services including a heat sensing fibre optical cable which triggers the fire systems response.
• Street Lighting: optics plays a key role in implementing lighting with safety to pedestrians and drivers, 6 different combinations of optics were implemented to allow ideal illumination to each of the areas.
• We at Kerfoot would be honoured to be recognised as winners, it reflects the commitment our team has to completion of projects exceeding client’s expectations on time, budget, quality, scope and safety.
• Our ability to meet client’s needs on time and budget with high attention to innovation, safety, quality and the environment shows how well we adapted to the changing environment of today and over the past 47 years.
• The implementation of little-known technologies such as the heat sensing fibre cable and the systems integration for remote operation and management of all services in the substation, tunnel and street lighting that are capable of operating with zero fault tolerance in a live environment where the safety of the light rail users is paramount is an unique accomplishment .

Project Description

• Facing substantial business grown over the last years, Stryker was faced with the need to expand its warehouse space and better their fulfillment strategy.
• The Arndell Park Fulfilment centre was envisioned to create a consolidated location for fast fulfilment of orders with the added possibility of automation of based repetitive tasks, freeing up Stryker’s team to focus on their customers, not the parts they stock.
• Kerfoot was approached through Multibuild, with whom we have had a relationship spanning over 2 decades, to help map out the electrical and communications needs to make the new fulfilment centre a reality.
• We then, mostly in house, designed and subsequently installed the complete electrical and communications infrastructure required to meet the needs of Stryker’s growing business.
• The first stage was consisted in analysing the existing power availability at the selected location to determine if it was enough to accommodate the business needs, it became clear that it was not the case.
• We then moved to Level 3 design to determine what was require to augment the LV supply into the building, while that was happening we went moved into the designing the upgrade to the existing, dated, electrical installation, resulting in the replacement of the main switchboard and many of the DBs throughout the building to ensure AS3000 compliance and future proof of the installation.
• Throughout the design process, it was uncovered that the power in the area is not ideally reliable, what led to the further investigation and the addition of a backup generation to the project in order to safeguard the data integrity and enhance the reliability of the server to be housed in new server room.
• From the level 3 design it was determined that the existing LV switching equipment and an external MSB feeding Stryker’s new premises and another business were in need of upgrade, we then proceeded with level 1 works to carry out the upgrades and Level 2 works to relocate and upgrade the metering to bring it up to code.
• On the communications network side, we investigated the available cabling technologies on the marked and recommended the installation of a hybrid solution with decentralised copper and fibre networks using OM3 and Cat.6A cables to ensure maximum lifespan and optimum network speeds without any bottlenecks limiting the performance of the network.
• To ensure compete coverage of the installation, a wireless mesh network was also introduced to enable handheld and mobile devices to be used throughout the warehouse, with no black spots in between the racking or fulfilment equipment.
• The last piece of the puzzle was to add simplified emergency and exit lighting testing compliance throughout the warehouse, for this we selected a Dali System with Rapix centralised networked monitoring and managing of the system.

 
Project Accolade

• The fulfilment centre empowers Stryker to move the focus from the parts to the people through automation and centralised control.
• Kerfoot’s involvement in the design from conception stage provided cost savings throughout the project through minimum waste, no changes during construction and maximum lifespan of the installation.
• Upgraded Electrical infrastructure, best in class communications networks and the convergence of technologies used in this project exemplifies the advantages of engaging an electrical contractor with in house design capabilities over a design capable only alternative to ensure the solution are affordable, practical, workable with no loss of quality, compliance or longevity and locked in cost savings from day one through integrated design and installation approach.
• We at Kerfoot would be honoured to be recognised as winners, it reflects the commitment our team has to completion of projects exceeding client’s expectations on time, budget, quality, scope and safety.
• Our ability to meet client’s needs on time and budget with high attention to innovation, safety, quality and the environment shows how well we adapted to the changing environment of today and over the past 47 years.

Project Description

• The Parklea Correctional Centre is a privately managed Australian maximum and minimum-security prison for males.
• The centre is located at 66 Sentry Drive, Parklea within the Blacktown Local Government Area approximately 40 km north-west of Sydney.
• The NSW Department of Justice proposed an upgrade to the Parklea CC to meet the needs of the State’s growing prison population.
• The upgrade of the centre was to be undertaken in a number of stages as detailed below;
• – Stage 1 – driveway realignment & new visitor carpark.
• – Stage 2 – minimum security prison upgrade, associated facilities and second visitor carpark.
• Stage 1 works were completed as an early works package and Kerfoot were engaged to complete stage 2.
• Stage 2 consisted of a new 150 bed minimum security prison that is to be located to the south of the existing complex where the current visitor car park is located.
• The new minimum-security accommodation is proposed to be housed in three (3) two-storey buildings, each arranged with four (two-up,two-down) self-contained units.
• In addition, the following associated facilities are proposed:
• – Visits Centre
• – Officer Post, Programs and Support Services Buildings
• – Open space / playing field.
• – Macem perimeter fence (5000 mm high).
• – Second visitor’s car park.
• – Alterations to the existing accommodation
• – Energy Complex
• Kerfoot was engaged to complete the design finalisation and installation of the following services.
• Decommissioning and make safe of all existing services on site
• Map out existing services that were to be retained or altered
• Maintain Power to the existing minimum-security facility for the duration of the works.
• Electricity supply to the site. (Level 1 High voltage augmentation Works) including:
• Over 1KM of reticulation running from a local street across 3 Private properties, a Sydney water easement an under bore below the prisons lake, through the maximum security sterile zone and through the live prison car parks.
• Connect in to 2 existing substations
• Supply & install a new 1000Kva substation & cabling to suit
• Replacement of existing high voltage switch gear with in an existing substation
• Consumer mains connected to the new substation
• Main switchboard.
• Main Switch Board culvert & structural Steel to hold the main switch board in place
• 500 Kva Diesel generator with 12 Hrs integral fuel system, ATS and load shedding BMS monitoring.
• Power factor correction unit
• Distribution Boards with essential, Critical & Nonessential sections
• Mechanical Switch Boards including all control for the mechanical system
• Surge protection and filtration for Critical circuits
• Electricity metering & BMS connected power meters
• NOTE: All services, Fixtures, Fittings & accessible items installed were to suit all prison environment requirements. This included the use of Vandal covers, High IK rated fittings, Tamper proof Screws, Steel plates & pre-installed fixings in concrete walls.
• New site wide in ground pit & conduit networks for power, Lighting & Fire services reticulation.
• All inground excavation, Shoring, Benching, and civil works for the installation of this pit & conduit network.
• Underbore’s for services to reticulate under the existing roads
• Civil works & Building works in locations were services connected in to the existing prison including:
• Demolition of path ways & road surfaces
• Earth Works
• Drainage & Pits
• Re installation of path ways & road surfaces
• All required ground & soil testing the engineer the correct footings
• External Light footings & Supports
• External Lighting Poles & Fixtures.
• Lighting protection system for each of the buildings to comply with Australian standards.
• Cable containment and support systems for power, Lighting, Mechanical electrical & Fire services reticulation.
• The off-site installation of all cable reticulation with in precast concrete walls (over 500 panels) including:
• 3D coordination (Lead by Kerfoot)
• Conduits
• Block outs for all electrical services
• Pre-installed fixings
• Submain Cabling for all distribution boards, Generator, PFC Mechanical switch boards, Fire Panels, Hydraulic panels, Security & communications panels.
• Cut over of the existing minimum security prison on the new main switch board while the prison remains operational
• General & Specialised power outlets for all area
• General & Specialised lighting for all areas
• Body Protect installation in accordance with AS3003
• Lighting control systems with override control for prison guards
• Emergency and exit lighting and computer monitoring systems
• A Complete Fire Detection System using the following methods:
• VESDA system for all prisoner’s areas
• EWIS Systems
• Smoke detection
• The complete mechanical electrical system including:
• Supply and install 5 new Mechanical Switchboard
• Supply and install Air Conditioning Unit Control Panels
• Supply and install Comms Room Monitoring panels
• Supply and install Power & control to the following equipment throughout all buildings
• Condenser Units
• Fan Coil Unit
• Exhaust Fans
• Natural Ventilation

 
Project Accolade

• When awarded this Project Kerfoot understood that there was no room for error, everything on this project needed to be considered and planed moths in advance as there was to be no second chance when the prisoners moved in.
• The preparation, staging and installation practices Kerfoot implemented on this project were meticulous and resulted in a seamless transition from existing to new facility’s without affecting the day to day operations of the prison.
• The project was a huge success has resulted in brand new installation processes that other contractors are using across the industry in similar projects.
• For Kerfoot to be recognised as a winner in this category means a lot to the entire team. This project involved preparation, staging and installation practices we as a team have never undertaken before. it confirms our position as a top electrical contracting and management company within the industry. This shows our ability to adapt to any of our client’s requirements, overcoming Time, Staging, Design, Implementation and Technical boundaries, however difficult they may be to deliver a successful project.
• Our keen understanding of the client’s needs and the challenges faced led us to develop innovative design & install methods that resulted in a highly successful project and a complete turnkey solution.
• Our team successfully carried out large scale complex works without any disruption to the public or prison operations, there were no injuries or loss of time throughout numerous difficult installations.

Project Description

• Design and construct of the electrical and dry fire package
• Installation of 2x 1000kVA substations and associated infrastructure
• 500kVA Generator installation and associated infrastructure and Switchboards
• UPS Installation for backup of critical security and comms equipment within all new buildings
• Light and Power installation including associated DBs and sitewide underground infrastructure
• 2x new 1600A MSBs
• PFC Equipment
• KNX Lighting control with sitewide override from New Main control room
• Dry fire detection and BOWS including incorporation of existing system to new system.
• Stage 1 Included the fit out of an existing building on site to house inmates whilst works to construct the new buildings took place.
• Stage 2 involved the demolition of six existing cottages and re-diversion of services to allow the construction stage to proceed. This involved the design and construct of three new 48 bed minimum security blocks, 1x segregation unit and a new multipurpose wing. Also involved during this stage was the complete design and construct of the new gatehouse building and associated infrastructure including HV works and generator installations for the new supply infrastructure for the entire centre.
• Stage 3 of the build resulted in the demolition and re-diversion of services of the last four cottages to make way for the new construction to proceed. This stage consisted of the design and construct of the two new 48 bed medium security blocks and the demolition of the old gatehouse building to make way for the design and construct of a new reception/admin building in its place. The overall design also allows for the infrastructure for four future blocks to be built and connected.

Project Accolade

• Construction was undertaken in and around an operational prison, creating many challenges as work could not impact prison security. Due to new infrastructure, many LV and HV shutdowns were required, resulting in the detailed design of critical equipment to ensure a smooth transition from old infrastructure to the new network. Kerfoot spent many months co-ordinating with services including security, CCTV and access control. This involved interaction with all major stakeholders of OMMPCC and co-ordination with the John Morony and Dillwynia facilities which also share the site. All works required the approval of the Governor prior to being able to proceed.

Project Description

• While the NBN continued to expand, the requirement for more power came hand in hand with the development and implementation of new technologies. Along with this need it is imperative that these systems are backed by appropriate power gen.  We had the opportunity to be the main contractor involved with a power upgrade at a prominent Telecommunications Facility in the South of Sydney.
• The project saw us step outside of what a standard electrical contractor would normally do. We took on the challenge, consisting of demolition of existing brick walls, design and installation of structural steel, design and construction of fire rated walls and fire rated systems creating a new fire rated room which housed the New 1000A Main Switchboard, provision of temporary back-up generator integrated into the existing installation to allow full automatic operation during the demolition of the existing power gen system, the installation of an in-room 750kVA Generator with associated fuel system, intake and discharge air systems along with full acoustic treatment within the room meeting the specified target noise levels for the residential area.
• The new system was successfully commissioned and put online with all construction taking place in a fully operational facility where power is critical. Cutovers were timed and scheduled down to the minute and completed without fault.  Another successful project for both the team and the client.

Project Description

• The scope of the project involved:
• The timely procurement of products/items with a prolonged lead time.
• Relocation of existing potable water services from proposed substation easement.
• Construction of retaining structures in accordance with the structural engineering documentation to meet Ausgrid requirements.
• Substation relocation site works as per Level 3 Electrical Engineering documentation and energise the new substation.
• Decommissioning and removal of an existing substation and all redundant associated services.
• Construction of a new main switch board room and all associated services and metering.
• In ground works (pit and pipe) for the new submains and future comms cabling.
• Supply and installation of new 1600A main switchboard, including all testing and commissioning.
• Decommissioning and removal of existing main switch board and removal of all the existing redundant cabling and associated services.
• Supply and Installation of new low voltage consumer mains and submain cabling to reconnect supplies to all existing switchboards in affected buildings.

Project Accolade

• Kerfoot were not initially asked to tender this project. As the scope of works unfolded it became clear this was going to be an incredibly difficult undertaking. At this point the Electrical Engineer sought Kerfoot to join the tender list. The complete relocation, construction and installation of a new state of the art 1600A MSB was dwarfed by the challenging layout. Kerfoot’s can do attitude and resolute ITP process including ISO9000 certification and adherence to GC21 saw us step into the complete management of the site involving civil works and the unexpected removal of 600 Tonnes of Sandstone from site.