Vale Canada Limited
The Huronian Power Line is a crucial segment of Vale’s electrical infrastructure in Sudbury, Ontario, originally constructed in the early 20th century and well beyond its 40-year service life.
This quad 69 kV feeder system spans from South Mine to Vale’s tailings buttress and crosses key infrastructure like highways, rail lines, and mine access roads. Its deterioration threatened operational reliability and safety. The design challenge was to avoid pole structures within the dam footprint while ensuring adequate clearance for ongoing tailings dam upgrades. The corrosive conditions in the tailings area required durable materials that could withstand harsh exposure.
SCOPE
BESTECH was tasked with detailed engineering for the Huronian Pole Line replacement. This involved coordinating power systems, civil, and structural engineering to design four new quad 69 kV feeder lines that meet operational and infrastructure planning needs. Fiberglass-reinforced polymer (FRP) poles were selected for their corrosion resistance and longevity, reducing maintenance demands and future disruptions to tailings operations.
The design utilized long-span structures to keep poles out of the dam footprint and meet clearance requirements for heavy equipment. The scope included designing shield wires and optical ground wire (OPGW), grounding and lightning protection studies, constructability reviews, permitting coordination, capital cost estimation, technical bid evaluations, and developing a demolition plan for the existing infrastructure. BESTECH also provided construction and commissioning support for a smooth transition to the new installation.
OUTCOME
The upgraded Huronian Pole Line significantly improved the reliability and resilience of Vale’s power distribution system while addressing the environmental and operational demands of the tailings facility. The use of FRP poles and innovative span design ensures long-term performance in corrosive conditions and supports dam upgrades, enhancing safety for personnel and infrastructure.