Switchrooms

Modular Transportable Electrical Switchrooms

Ampcontrol has supplied modular electrical switchrooms to every industry and environment. From open cut mines, processing operations and infrastructure projects, we work closely with our customers to develop a solution that is unique, safe and compliant for their application.

Our cost-effective switchrooms are manufactured to meet Australian standards and can have up to a 100-year design life. They are fabricated in Australia to meet structural demands, site requirements, fire ratings, environmental considerations and transportation requirements across a variety of applications, including:

  • Mining
  • Network substations
  • Infrastructure projects
  • Processing operations
  • Motor and drive control centres
  • Communication centres
  • Distribution boards

 

High Voltage Infrastructure

From a single piece of equipment to your sites power reticulation, Ampcontrol’s power distribution systems are highly reliable, safe and flexible for all medium and high voltage mining, refining, renewables, traction, power utility and industrial applications.

We have five decades of experience designing, manufacturing and servicing high voltage electrical solutions that improve safety, maintain efficient options and meet stringent regulator requirements.

We don’t just manufacture power infrastructure, we partner with you to integrate our equipment into the electrical system and provide lifecycle management support to ensure optimised performance and safe, reliable power generation and distribution.

To ensure your operations can continue efficiently, and assist with reducing capital expenditure, we can also supply a range of reconditioned substations, transformers and cables for sale or short or long term hire.

Mining and Tunnelling

We are leaders in power infrastructure and understand the requirements of powering underground coal mines and hard rock mines, tunnels and oil and gas applications.

Our approach to these markets has been simple; design, manufacture and deliver electrical solutions that will improve safety, maintain efficient operations and meet stringent regulatory requirements.

We believe there is still value in knowing and seeing your electrical partner and this is why we don’t tackle customer challenges with a ‘one-size fits all’ approach. All of our electrical solutions are customised to specifically address your requirements. To do this we take a big picture look at the needs of an individual application, making full electrical package solutions our most valuable offering.

To ensure your operations can continue efficiently and assist with reducing capital expenditure we can also supply a range of reconditioned hazardous area power distribution products for sale or short or long term hire.

Supporting transformers throughout their lifecycle

High Voltage Transformer

1. Engineering

It all starts with engineering. Ampcontrol’s highly experienced transformer engineers assess your requirements and develop innovative and appropriate solutions. Our design engineers work with your project from concept through to final commissioning, and use the latest transformer design software including SPARON, VLN and Anderson programs and 3D mechanical design applications.

2. Coil winding

Ampcontrol’s transformer manufacturing facility in Tomago, NSW, Australia, features a dedicated and separate clean winding space, with a range of winding machines with expanding mandrels to suit required sizes. We work with copper aluminium, paper (including thermally upgraded paper) and Nomex coverings and continuously transposed conductors. We have a vertical winding machine for larger power transformers and a foil winding machine for smaller distribution transformers.

3. Core slitting and lamination cutting

Using slitting and mitre cutting lines transformer cores are slit and cut to accurate geometric shapes requiring precision engineering.

4. Assembly

Our experienced assembly team build transformer cores, assemble windings onto the core, build the cleat and lead arrangements and manage the drying and tightening process. We utilise four drying ovens rated up to 220°C including a vacuum oven which features cyclically applied heat and vacuums ensuring moisture and water vapour are removed from the core and winding assembly.

5. Tank production and repair

We manage the production and repair of tanks for liquid cooled (oil and other fluids) power and specialist transformers along with GNAN tanks for a range of challenging applications. Our stringent fabrication quality control standards ensure high quality transformer tanks.

6. Testing

Ampcontrol’s experienced test engineers undertake comprehensive testing of all of our transformers. Our transformer testing facilities feature a high voltage test bay including 1000kV/75kJ impulse testing certified to ISO/IEC 17025, DDF, SFRA, PD, noise level and harmonics testing; a routine test bay with 11kV mains connected test supply and regulator to conduct load loss, no load loss and temperature rise testing up to 75MVA 132kV; a partial discharge free high frequency generator for induced over voltage and partial discharge testing and power frequency withstand voltage testing up to 350kV.

7. Install and commission

Our team of experienced technicians and engineers conduct onsite assembly and commissioning. We also provide supervision services to work with your own competent installation and service team to ensure Ampcontrol transformers are installed and commissioned to the highest standards.

8. Maintenance, overhauls and upgrades

Maintaining, overhauling or upgrading your transformer can be a cost and time effective alternative to capital expenditure on new equipment. Our transformer overhaul work encompasses:

  • Replacement gaskets and service bushings
  • Winding repairs and replacement
  • Controlled oven drying of windings
  • Testing and filtering of oil including a mobile Fuller’s Earth Oil Treatment facility
  • Tank repairs and modifications, repainting, vacuum and pressure testing
  • Fitting of additional protection devices and cable boxes
  • Tap changer services
  • Oil leak repairs
  • Full testing to Australian standards

Refurbished Equipment – hire and sale

Ampcontrol’s refurbished second hand power equipment includes substations, transformers and cables available for purchase, short or long term hire or via service exchange to enable you to temporarily replace critical equipment during overhaul and service work.

If you need a piece of electrical equipment to keep you running during maintenance or are looking for a permanent addition to your site our range of refurbished power infrastructure equipment is available for quick dispatch.

We can also provide after sales service for purchased or hired electrical equipment including electrical system design, service contracts, engineering, periodic maintenance and statutory testing and commissioning.

Power Quality

At Ampcontrol we believe in creating and maintaining the highest quality power possible for our customers through an in-depth understanding of power usage and electrical efficiencies.

Ampcontrol is one of Australia’s leading designers of power quality solutions for mining and heavy industrial applications. Ampcontrol member company Captech, provides power quality and power factor correction solutions for the commercial and industrial industries.

Captech’s aim is to improve power quality issues, optimise power usage, reduce power costs and increase safety and compliance; outcomes which are critical to energy intensive sectors such as mining, industrial, commercial and power utilities.

Captech’s team of highly qualified and skilled engineers can assist in providing a power quality solution to suit specific applications. Comprehensive system support and analysis ensure your installation is performing at its best.

Transformers

Ampcontrol’s robust, high specification, custom engineered and manufactured transformers are known for their quality and durability.

Ampcontrol’s quality, Australian, transformer designs cover dry and oil type transformers for electrical distribution substations, power generation, voltage regulation, underground mining, traction and refining applications. We are also experienced in the design and manufacture of transformers using alternative cooling fluids, including ester dielectric fluids, for service levels up to 132kV.

We don’t just manufacture transformers, we add value through our solutions based approach to specialised transformer projects. With our broad capabilities and product ranges we are uniquely positioned to integrate our power and distribution transformers with other Ampcontrol products and capabilities including fixed modular, relocatable and transportable substations as well as third party products.

To ensure you get the most out of your infrastructure we support customers with a range of transformer engineering, testing and services across the full transformer lifecycle and have a comprehensive range of refurbished and reconditioned transformers for sale or short to long term hire.

Transformer lifecycle diagram

1. Engineering Design

Our quality, Australian, transformer designs cover dry and oil type transformers for electrical distribution substations, power generation, voltage regulation, underground mining, traction and refining applications.

Our highly experienced design engineers work with your project from concept though to final commissioning and use the latest in transformer design software.

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2. Manufacture

At over 6400m2, our specialist transformer facility in the Hunter Valley, NSW, has the capacity to manufacture transformers up to 75MVA, 132kV.

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3. Testing

Our comprehensive testing services, including workshop and field high voltage testing, can be conducted on new and in-service transformers.

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4. Installation and Commissioning

We conduct onsite assembly and commissioning of our transformers led by our experienced technicians and engineers as well as supervision services to work with your own competent installation and service team.

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5. Oil Sampling, Testing and Diagnostics

Our transformer oil sampling services are provided by experienced personnel, who have vast experience in the electrical industry and can assist with all your diagnostic requirements.

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Ampcontrol can undertake all major and minor insulating oil analysis tests, condition assessments and oil material characterisation, electron microscopy and specialised analysis.  Our facilities provide you with access to a full suite of testing capabilities, supported by experienced staff, with all work compliant with ISO/IEC 17025.

6. Oil Regeneration

With mobile plant capable of performing both on and offline oil regeneration we can help maintain the chemical properties of your transformer insulating oil; reducing unplanned outages and maintenance costs while maximising transformer life and reliability.

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7. Maintenance

We know the operational value of your high voltage infrastructure, which is why we provide a range of high voltage and onsite services to ensure operational availability and compliant management.

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8. Overhauls, upgrades and rewinds

Overhauling, upgrading and rewinding your transformer can be a cost and time effective alternative to new builds.

Our Australian transformer workshops in NSW and QLD have the capacity to overhaul transformers up to 75MVA, 132kV weighing up to 80 tonnes.

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