Karuah Plant Upgrade – Electrical Design

CDMS Electrical Engineers was engaged by Hunter Quarries to provide the electrical design for the upgrade of the crushing and screening plant at their Karuah facility. The upgrade would allow them to provide a bigger range of weights and sizes in their blue metal rock products. For further details on the Electrical Design services provided by CDMS Electrical on this project please contact the CDMS Electrical Team on +61 (08) 9421 9060.

Project Brief


An additional crushing and screening plant was added in conjunction with the original, to provide a number of new gravel products, in addition to their original products.


Hunter Quarries have a vast knowledge in the quarrying industry, specialising in supplying Blue metal rock in various weights and sizes. Hunter Quarries durable Andersite deposit is suitable for all engineering purposes including landscaping, building, concreting, asphalting and large projects. They are the major gravel supplier in this region.

Project Objectives

CDMS’s objective was to implement a detailed engineering design whilst meeting the criteria below:

  • Review the current site electrical infrastructure and provide a detailed risk assessment;
  • Develop integration requirements for a new switchboard with basic functionality specifications;
  • Review and adapt control functionality for the complete plant;
  • Develop SCADA/PLC/HMI control and logic sequencing, providing fully documented configuration files; and
  • Provide onsite control system commissioning.


  • No major site constraints – however the scope of works changed several times over the course of the job
  • The graphic screens for the new system were required to mimic those of the original plant controls. This synergy was sought to: allow the operators to be conversant with and able to use either plant; minimise the training required for the operators; and reduce the risk or operator error.

Our Approach

In conjunction with the client, CDMS established the functional requirements of the crushing and screening plant after having reviewed the original site electrical infrastructure. The electrical design of both Power and Control systems was completed to allow the electrical switchboard to be built and installation to follow. FAT testing of the switchboard was carried out prior to shipping to site, with electrical on-site commissioning finalising the project.