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PROJECT
Gold Coaster: Electrical and Controls Systems Replacement

CLIENT:
  • Dreamworld

 

THEME PARK SUPPORT SOLUTIONS

(Utilising specialist Electrical Engineering and Trade Services of PFI)

  • Control System Design and Development
  • Electrical and Instrument Design
  • Functional Safety Planning, Design and Implementation
  • Panel Manufacture
  • Demolition of existing systems
  • Installation and commissioning
  • FAT, SAT, commissioning and testing
  • Regulator Compliance and Handover to Dreamworld
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CHALLENGE

The Gold Coaster ride at Dreamworld first started service at Lunar Park in the 90s. It was relocated and began service at Dreamworld in the early 2000s. The ride electrical and control systems had been in constant service for more than 15 years. While the passenger restraint system and pneumatic braking systems were recently upgraded, the control system and electrical components were approaching obsolescence. This project was proposed to replace the existing ride control system (RCS), track sensors and Variable Frequency Drive (VFD) together with other improvements to bring the ride up to the latest standards and extend the life of the ride for a further 15 years.

SOLUTIONS

TPS replaced the existing control system and its electrical components in their entirety. The electrical and control cabinets in the electrical switch room were demolished and replaced with a new suite of cabinets. The main switchboard and isolation switches were be upgraded or replaced and a new VFD for the lift motor installed. A new operator console including an enhanced HMI replaced the existing Main Operators Console at the station. The features of the HMI were expanded to include ride status and alarms together with details of the passenger restraint system. The new RCS system utilised the latest control system products and was designed to be compliant to the latest standards for functional safety and electrical design. In general, new field sensors were installed and gate control systems upgraded for reliability and appearance as well as safety performance.

Together with Dreamworld operational and maintenance personnel, new functional descriptions for ride operations, ride control parameters and ride sequence were designed, implemented, tested and modified to produce a better ride for all stakeholders.

The original system architecture was improved by bringing all the ride functions from the train and track together into the one safety PLC. Remote IO replaced field cabling as much as possible and communications used the established safety protocols.

The ride went offline immediately following the September school holidays and the ride was back on line for use by Dreamworld guests in time for the Christmas holiday period. On time and on budget.

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