Air Conditioning System Installation at South32 Worsley Alumina

Project Spotlight: 24/7 Cooling System Installed for Critical Electrical Building – South32 Worsley Alumina

Bunbury Refrigeration & Air Conditioning was engaged to deliver a tailored cooling solution for EDC700, a key electrical switch room at the South32 Worsley Alumina site in Collie, Western Australia. The project was part of a site-wide electrical infrastructure upgrade and required a high-performance, continuous-use air conditioning system that could operate reliably in a harsh environment.

Background and Cooling Requirements

The client required a practical, durable solution that would deliver effective cooling for their building, while also being suitable for the conditions of a working mine site. The system needed to be easy to maintain, compliant with site safety and installation standards, and capable of handling regular daily use.  

As part of the site upgrade, the building was fitted with new high voltage switchgear and battery systems. These sensitive systems require stable, controlled temperatures to ensure optimal performance and long-term reliability. Without active cooling, rising internal temperatures posed a significant risk to the operation and lifespan of the equipment, particularly during periods of high ambient heat.  

The Solution

To meet these conditions, our team supplied and installed a custom refrigerated cooling solution using under-ceiling cassette air conditioning units. This system was selected for its ability to:

• Operate 24/7 under demanding conditions
• Manage continuous high heat loads
• Maintain stable ambient temperatures across open-plan internal spaces
• Provide easy access for servicing and long-term maintenance

The equipment was installed in line with site-specific safety protocols and project timelines, with minimal disruption to operations.

Overcoming Site-Specific Challenges

While the scope of works was clearly defined at the outset, as is often the case on live industrial sites, practical challenges emerged during installation. Once on site, it became clear that the air conditioning units could not be installed exactly as originally scoped, due to space limitations and unforeseen structural constraints.

Our team worked closely with site personnel to modify the installation approach, reconfigure mounting locations, and adjust the layout of pipework and interconnects — all while maintaining compliance with South32’s safety and operational standards.

Thanks to effective problem-solving and flexible delivery, we were able to successfully adapt the project in real time and complete the installation without compromising performance, safety, or timeline.

Managing Risk Through Smart System Design

In environments like EDC700, the risks of inadequate cooling are significant but often avoidable. Without an effective system in place, excess heat can shorten the lifespan and reduce the integrity of sensitive electronics, and lead to unplanned shutdowns of critical equipment.

These types of failures can be extremely costly, not only in terms of equipment replacement but also in potential downtime, operational delays, and lost productivity. By installing an active cooling solution designed to meet the building’s increased thermal demands we helped mitigate these risks and provide a reliable long-term outcome for the client.

The Result

EDC700 is now actively cooled by a purpose-built air conditioning system designed for continuous, high-demand use. The system maintains critical temperatures, supports the performance of upgraded electrical components, and reduces dust ingress — a significant improvement from the ageing pressurisation system previously in place.