Hard Rock Crushing Plant Upgrade – Possum Brush
When Level Electrical Taree was engaged to upgrade the motor control centre at a hard rock crushing plant on the Pacific Highway in Possum Brush, the goal was clear: bring the site up to current electrical legislation while making it safer, smarter and more efficient.
Led by Jeff Brown, the team delivered a complete electrical upgrade that has significantly improved both safety and productivity for the operator.
Bringing the plant up to standard
The existing setup was operating on outdated systems, presenting both compliance and safety risks. Level Electrical Taree designed and installed a new control circuit, converting it from 240V AC to 24V DC - a critical change that removed the risk of electrocution from the control circuit.
The motor control centre was also upgraded to allow remote isolation of motor drives, grouped in zones. This innovation greatly reduced the chance of arc fault injuries during isolation and maintenance procedures.
Smarter systems, safer operations
A new Allen-Bradley PLC and SCADA system was installed to automate the entire plant. The upgrade not only improved operational control but also provided valuable real-time visibility, making fault-finding faster and safer for onsite teams.
“The new system has completely modernised the way the plant operates,” said Jeff Brown.“We were able to deliver a solution that improves compliance, boosts productivity, and most importantly, keeps people safe.”
A long-term partnership
Nearly a decade later, the project continues to prove its value. Level Electrical Taree has maintained the site’s electrical systems ever since, with team members now on-site almost daily. Their deep understanding of the plant’s operations ensures consistent reliability, proactive maintenance, and ongoing compliance with evolving safety standards.
The outcome
The upgrade achieved full legislative compliance and delivered measurable improvements in safety and productivity. The combination of careful planning, technical skill and modern automation has positioned the plant for reliable long-term performance.
Level Electrical Taree continues to set the benchmark for complex industrial projects - from heavy manufacturing sites to large-scale automation and control systems. Known for their precision, reliability and commitment to performance, they remain the trusted electrical partner for this site and many others across the region.
Project completed: December 2016
Project lead: Jeff Brown, Level Electrical Taree
Partners: Haymans; Adam Berwick (PLC and SCADA programming and design)
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