Current and recent past projects successfully completed by Systems Insight:

• O'Donnell Griffin Pty Ltd - New Generator Paralleling Control Systems with Woodward EGCP-2 Controllers, operating 5 x Diesel Generators at Hewlett Packard Data Centre, Melbourne.
• Energy Power Systems Aust. Pty Ltd - Telstra Exhibition Exchange, Melbourne - New paralleling control systems with Woodward EGCP-2 controllers for 2 x CAT Diesel Generators
• O'Donnell Griffin Pty Ltd - New Generator Control Systems for RAAF Base - Townsville, Queensland.
• Energy Power Systems & Thames Water Projects - West Bangkok Water Treatment Plant
• Austin & Repatriation Hospital, Melbourne - New Standby Generator Control System and HV Power Reticulation Management System, featuring utility mains paralleling using Woodward EGCP-3 controllers.
• Office Tower - 460 Lonsdale St, Melbourne - Standby Generator Control System.
• Victorian County Court - Lonsdale St, Melbourne - Standby Generator Control System
• Energy Power Systems - Integrated Control Systems for CAT Hire Generator Fleet
• Woodside Petroleum - Kellogg Joint Venture - Custom Standby Generator Control System
• Sydney Ferries - Bridge mounted Engine Control Panels
• Crown Entertainment Complex - Automation of High Voltage Ring Main System
• Alcoa Australia - Anglesea Power Station
• Eltin Mining Project - Paralleling & Switchgear Cubicles
• Optus Exchange - Sunshine, Victoria.

Emergency Power Control System and Air Circuit Breaker Switchboards for Thames Water Projects, West Bangkok Water Treatment Plant, Bangkok, Thailand.

Details:
This project was completed in May 2004 and included design, manufacture and commissioning of PLC operated emergency power control systems for five CAT Diesel generator sets. Generators are sized between 1400kVA and 1750kVA, with each genset installed by EPSA to a customized 40ft container. Control panels and Air Circuit Breaker cubicles were installed and wired in the containers by Systems Insight. Each generator system was fully tested in Australia prior to shipment to Thailand. These control systems feature Woodward EGCP-2 control units for each generator and Multilin SR-489 generator management relays. A 'Modicon 984 Compact' PLC is installed as a supervisory controller for each generator set, with all PLC software engineering provided by Systems Insight.

Emergency Power Control System for new office tower - 460 Lonsdale St, Melbourne.

Details:
Design, manufacture and commissioning of a PLC operated emergency power control system. The new system operates a 600kVA CAT Diesel generator set on mains failure and automatically transfers selected mechanical services loads and the elevator circuit to generator supply. Loading to generator is according to a prioritised sequence programmed into the PLC. The system also includes control and data interfaces to the Building Management System and Elevator System, to call restricted operation of mechanical services plant and lifts whilst on emergency power. The PLC used for this project was a 'Modicon 984 Compact' using Modicon 'Concept' programming software.

Emergency Power Management System for new Victorian County Court - Corner of Lonsdale St. and William St, Melbourne.

Details:
Design, manufacture and commissioning of a PLC operated emergency power management system. The new system operates a 1250kVA CAT Diesel generator set on sensing failure of either of two incoming mains supplies. The PLC used for this project was a 'Modicon 984 Compact' using Modicon 'Concept' programming software. The PLC activates automatic load shedding by operating circuit breaker transfer switches on the main switchboards and load shed contactors in the electrical distribution boards. It also interfaces with the Building Management System and Elevator system to call restricted operation of mechanical plant, lifts and escalators whilst emergency supply is connected.

Loads are reconnected to generator supply sequentially, according to priority. The system connects as much load as possible to the generator, whilst maintaining a safe operating buffer for transient loads. Generator loading is continually monitored and load shedding to fine tune the system is activated automatically should load rise beyond an acceptable level.

Energy Power Systems (Australia) Pty LTD - Generator Control Panels for New Hire Generator Fleet.

Details:
Design, manufacture, installation and commissioning of generator paralleling control panels for EPSA's new Diesel generator set hire fleet. Systems Insight has been selected by Energy Power Systems to provide a new control panel to suit a variety of different generator sets and to be suitable for a range of hire applications. The proprietary CAT EMCP II+ panel has been completely removed and replaced with this new control panel, which features a "Woodward EGCP-2 Engine Generator Control Package" as the primary controller.

Generator Control system for Woodside Petroleum, Kellogg Joint Venture.

Details:
Design, manufacture, installation and commissioning of a generator control system to operate a CAT 3516B 1800kVA Diesel generator set. This project required customisation of the standard CAT EMCP II+ control panel to include a significant amount of customer specific equipment and a marshaling cubicle for site interfacing. The project also included a remote mounting EMCP II+ control unit, installed by Systems Insight to a separate cubicle.

Engine Monitoring System for Sydney Ferries.

Details:
Design, manufacture, installation and commissioning of custom engine monitoring panels to the bridge and engine rooms of a fleet of catamaran type ferries. The panels connect with newly installed CAT marine diesel engines. An attractive etched perspex panel is used to mount a variety of standard CAT gauges and control equipment. The bridge mounted panel is connected via a pre-wired cable loom to a separate panel located in the engine room.

Crown LTD - Automation of High Voltage Ring Main System

Details:
PLC and SCADA engineering for automation of the High Voltage ring main system at Crown Entertainment complex. The new PLC software written by Systems Insight interfaces the existing Power Distribution Management PLC system with Merlin Gerin Talus 200 RMU isolator controllers. The Talus 200's indicate any fault in the HV ring system to the PLC and the PLC responds to automatically isolate the faulty section of HV cable. The ring is then reconfigured by the PLC, which commands the Talus 200's to operate specific HV isolators on the affected ring main system. The PLC controls a total of 34 isolators on seventeen high voltage ring main units. The project was performed in association with Schneider Electric, Melbourne.

Generator Control System for Alcoa Australia - Anglesea Power Station

Details:
Design, manufacture and commissioning of a generator paralleling control system for installation with a Caterpillar 750kVA Diesel generator set. The control system utilised an Allen Bradley SLC500 PLC with Woodward DSLC synchroniser and load control. This system allowed the generator to be paralleled with the mains for both no-break transfer and for load testing. In load test mode the generator is paralleled with the mains and ramped to a preset base-load level to provide sufficient load for testing.

Systems Insight also designed and provided an 800 amp air circuit breaker paralleling switchboard for this project.

Energy Power Systems (Australia) Pty Ltd - Generator Paralleling Control system and switchgear cubicle for Eltin Mining Project, Western Australia.

Details:
Design, manufacture, installation and commissioning of a generator paralleling control system for two 240kW CAT 3306 diesel generator sets. This specially designed control system utilised Woodward EGCP-2 engine control units for each generator, whilst also maintaining the use of the standard CAT EMCP II+ control panels. Systems Insight also manufactured an associated switchgear cubicle, containing paralleling contactors and outgoing supply circuit breaker. For portability, the control panels connect to the CAT generators via flexible cables with heavy duty plug-in connectors. The entire system was installed to a cut-down shipping container for ease of transport to the job site in Western Australia.

Project: Generator Control System for Optus Exchange, Sunshine, Victoria.

Details:
Design, manufacture, installation and commissioning of a generator paralleling control system for one 2MW CAT 3516B diesel generator set. Primary control equipment for this system consisted of a Heinzman SiTec CGC engine speed control and paralleling unit and Omron C200 Alpha series PLC. The system also featured an Omron touch screen as a system monitor. The project was engineered by Systems Insight according to a highly detailed consultant’s specification.