Noveco Surfaces Electrical Upgrade:
- Maxwell
- Jan 16
- 3 min read
Updated: May 21
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Project Overview and Background
Maxwell Electrotech Pty Ltd was engaged as a consultant by Arnold Electrical Data and Instrumentation (AEDI) for the electrical upgrade of the Noveco Surfaces is expanding its production capacity with new tile manufacturing equipment, which will result in a significant increase in electrical load. This increase necessitates a comprehensive upgrade of the electrical supply and Main Switchboard (MSB) to accommodate the increased demand.
The electrical upgrade was planned in two stages:
Stage 1 - Installation of two manufacturing line Main Distribution Boards (MDBs) and connection of the new manufacturing equipment. Only essential equipment would be commissioned to ensure compatibility with the existing 500kVA supply transformer.
Stage 2 - Upgrade of the consumer mains and MSB following Energex's installation of a new pad-mounted transformer, which will allow the facility to meet its full operational capacity.
Project outcomes and impact
Maxwell Electrotech provided Noveco Surfaces with a fully compliant and future-ready electrical infrastructure plan. The final decision on the MSB location will ensure operational efficiency and prevent costly rework during Stage 2. Compliance with AS/NZS 3000:2018 and Energex guidelines guarantees long-term safety and reliability.
The identification and resolution of compliance issues with imported equipment added significant value to the project, helping Noveco Surfaces avoid potential safety hazards and production downtime. The project is on track for successful completion, with staged commissioning to minimise operational disruption.
The project facilitated the establishment of a manufacturing facility for producing stone from recycled glass while eliminating silica components. Deliverables included a complete electrical reticulation design, maximum demand and diversity calculations, an upgraded incoming supply, new main switchboard, distribution boards, sub-circuit distribution, and compliance verification for fault levels on imported equipment.
Project Deliverables
Electrical design & calculations
Completed detailed load calculations and cable sizing in accordance with AS/NZS 3000:2018/Amdt 3:2023 and AS/NZS 3008.1.1:2017.
Fault Current Calculations: A fault current analysis identified the maximum fault current at the MSB, requiring appropriately rated switchgear and protective devices to ensure effective response to short-circuit conditions and prevent equipment damage.
Voltage Drop Calculations: Conducted a structured review session with WDRC to confirm specification details before final submission.
Main Switchboard Design: The MSB was designed with a capacity of 2,500A and a short-circuit withstand rating of 50kA for 1 second to support increased load from new manufacturing equipment and future expansion.
Single Line Diagrams and Equipment Layout: Developed single line diagrams and specified switchgear, protective devices, and metering equipment, ensuring accurate cable routing and sub-main extensions.
Cable and Equipment Schedules: Developed detailed schedules for equipment and cables, specifying load ratings, installation routes, and termination points to ensure compliance and proper alignment with the final MSB location.
Compliance Inspection and Report
A major deliverable involved conducting a comprehensive compliance inspection of all electrical equipment imported from China. This introduced significant complexity and additional work due to widespread non-compliance with both IEC and AS/NZS standards.
Identified and Reported Issues: Over 60% of the imported equipment failed to meet compliance due to incorrect ratings, poor manufacturing quality, inadequate ventilation, and missing certification.
Provide Recommendations: Recommended replacing or retrofitting non-compliant equipment with Australian-compliant alternatives (e.g., NHP, Schneider, ABB) and provided a staged upgrade plan to minimise downtime.
Cost Impact and Complexity: Compliance issues added project complexity, requiring modifications and replacements, but Maxwell Electrotech's expertise ensured resolution without impacting the project timeline.
Challenges and issues overcome
The project faced significant challenges in ensuring compliance and operational readiness within a short timeframe. The existing switchroom failed to meet AS/NZS 3000:2018 requirements for clearance and emergency access, which required urgent structural modifications, including the installation of a new external access door and improved clearances. Coordination with Energex was essential to align the design with both internal and external installation guidelines, with detailed technical documentation provided for pre-approval.
Additionally, a major challenge stemmed from non-compliant imported equipment, which failed to meet IEC and AS/MZS standards. Maxwell Electrotech provided detailed recommendations for staged replacement, retrofitting, and reconfiguration to bring all equipment up to standard, ensuring safe and reliable operation. Despite these challenges, the electrical infrastructure was future-proofed to support future expansion without requiring major modifications, ensuring operational readiness on schedule.
