Center West Exports operates a large-scale carrot farming operation in Carnarvon, requiring efficient and reliable refrigeration systems to preserve produce quality during processing and storage. The existing infrastructure necessitated an upgrade to enhance operational efficiency, energy management, and system control.

MECS Electrical & Controls was commissioned to design, manufacture, and install a custom switchboard equipped with advanced Siemens controls. The integration of VSDs allowed for precise water flow management, while interfacing with the PLCs of the GEA ammonia compressors facilitated centralized control and monitoring capabilities. 

Execution Strategy: 

Design and Engineering: 
The project commenced with a detailed analysis of the farm’s refrigeration and water management requirements. A custom switchboard was designed to house power distribution components and Siemens control systems, ensuring seamless integration with existing equipment. 

In-House Manufacturing: 

The switchboard was fabricated in-house, adhering to stringent quality standards. This approach allowed for meticulous control over the build process and ensured that the final product met the specific needs of the facility. 

System Integration: 

Siemens controls were configured to manage water flow through VSDs, optimizing energy usage and providing precise control. A high-level interface was established with the PLCs of the four GEA ammonia compressor sets, enabling comprehensive monitoring and control of the refrigeration system. 

Installation and Commissioning: 

The switchboard and associated control systems were installed on-site with minimal disruption to ongoing operations. Comprehensive testing was conducted to validate system performance, including stress tests to ensure reliability under various operating conditions. 

Training and Handover: 

Operational staff received training to effectively manage and maintain the new system. Detailed documentation was provided to support ongoing operations and facilitate troubleshooting. 

Challenges and Solutions: 

• System Compatibility: 
  Integrating new controls with existing ammonia compressors required careful planning to ensure compatibility. Customized interfaces were developed to facilitate seamless communication between the systems. 

• Energy Efficiency: 
  Optimizing energy consumption was a key objective. The implementation of VSDs allowed for dynamic adjustment of water flow, reducing energy usage without compromising performance. 

• Remote Monitoring: 
  Providing the capability for remote monitoring and control was essential for efficient operations. The system was designed with advanced communication features, allowing for real-time data access and control adjustments from remote locations. 

Outcome: 

The project was successfully completed, resulting in a state-of-the-art control system that enhanced the operational efficiency of Center West Carrot Farm’s ammonia plant. The new switchboard and integrated controls provided precise management of water flow and refrigeration processes, leading to improved energy efficiency and streamlined operations. 

Client Feedback: 

Center West Exports expressed satisfaction with the quality of work and the professionalism exhibited by the MECS Electrical & Controls team. The seamless integration of the new system and the enhanced control capabilities were particularly appreciated.