Origin Energy's Shoalhaven Hydro Scheme
UGL undertook the major overhaul of Unit 1 at the 40MW Bendeela Power Station (BPS) in 2023.
Origin Energy Eraring Pty Ltd, a subsidiary of Origin Energy Limited, is the current operator of the Shoalhaven Pumped Hydro Energy Storage (PHES) Scheme (“Shoalhaven Scheme”). It comprises of two generating/pumping units at Kangaroo Valley Power Station, along with two generating units at Bendeela Power Station (BPS). The Shoalhaven scheme is situated in the NSW Shoalhaven District, approximately 160km southwest of Sydney, NSW.
Pumped storage hydro plants, such as Shoalhaven, will support the energy transition from coal in the electricity sector. These plants act as giant batteries, storing excess renewable energy that can be quickly fed into the National Electricity Market when required, usually when renewable sources are unavailable.
Details
Location
Shoalhaven District, NSWStatus
CompletedSector
UtilitiesExpertise
Challenge
Due to floods that damaged the roads, our team deferred the 2022 outage to 2023. The key to making the outage a success for UGL and the client, was working cohesively with contractors and suppliers already working and those yet to be familiarised onsite. UGL engaged with Origin’s project representatives continually to deliver milestones especially during the disassembly, removal, and transportation of the Main Inlet Valve (MIV) off-site for refurbishment by other contractors.
Scope of Work
BPS Unit one, 15-year major overhaul
The overhaul of BPS unit 1 included, but was not limited to:
· The major overhaul of the unit and its associated equipment, including interpreting and incorporating Origin’s original equipment drawings, specifications, maintenance instructions and multipart directives from Origin and its representatives
·Replacing and calibration of instrumentation
·Cleaning, measuring, and recording of all components requested by Origin
·Overhaul of generator 16kV pneumatic Isolator’s
·Rotor pole inspection and Rotor pole removal, Offsite refurbishment, and subsequent installation.
·Replacement of Generator Cooling Water (CW), lube oil and cooling air fan contactor and thermal overloads.
·Upgrade of condition monitoring system mercury in steel (MIS) to resistance temperature detector’s (RTD).
Planning and scheduling
To ensure project is informed, efficient and on track.
Maintenance
UGL conducted miscellaneous planned maintenance routines within the station as well as additional maintenance assistance provided at Kangaroo Valley Power Station on unit 3 & 4, completed in January 2024.
Stakeholder engagement
During the outage, other works need to be executed at BPS, and the key to this was UGL working closely with the other parties as per Origin’s standards and works agreements.
UGL also collaborated with subcontractors nominated to deliver the Load Commutator Inverter (LCI) upgrade and replace the input and output transformers and associated cabling and recommissioning and subcontractors assigned to work on Bendeela Station Generator Step Up Transformer (GSUT) replacement, 8kV starting circuit breaker, and associated site works.
Project highlights
Solutions
UGL implemented a self-perform strategy prioritising field efficiencies and cost-effective solutions for Origin. UGL’s skilled outage management team and experienced lead technicians, with extensive hydro and rotating plant experience, executed this methodology.
Highlights of the solutions also include:
· A challenge with GSUT (Generator step-up transformer) was being able to access through the rear doors, UGL’s highly skilled rigging and scaffold team devised a way to safely and efficiently extend the access doorway to ensure the GSUT schedule remained on time.
·Safety issues with weight and ergonomics when removing runner drain pipework in the draft tube area. UGL’s engineering team designed and manufactured jacking stands so the pipework could be removed and installed safely, efficiently and with an improved quality of installation.
Quality workmanship
The team ensured the quality of workmanship aligned with the technical demands and complexity of this project, delivering optimal results. The complexity of the requisite outage overhaul and maintenance scope of works, combined with the remote geographical location of the assets, presented an opportunity for UGL and Origin to collaborate. UGL, with our experienced local management and workforce team, worked in partnership to deliver a service framework that prioritised communication, innovative approaches, and transparency in decision-making.
