Australian Power & Energy News Vol 17 No 94 December 2013 by Australian Main Roads Construction News

Please see our editorial and advertisement on pages 20 and 21

VOL. 17 NO. 94 - December 2013

Print Post No. PP100000928

All enquiries phone: +61 7 5478 9432 Email Enquiries: apen@worldpacific.com.au Circulated to key personnel within all Power Utilities and Power Generators throughout Australia and New Zealand each issue

New Dawn for Iconic Snowy Mountains Scheme Special Feature Pages 4-16

Aurora Energy supports Raptor Refuge

URORA Energy’s long partnership with Tasmania’s Raptor & Wildlife Refuge of Tasmania facility was cemented today with the official opening of an Education Centre at the Kettering site.

Aurora CEO Dr Peter Davis said the Education Centre would complement the existing raptor rehabilitation aviaries on the site by providing education and awareness of raptor conservation issues for school and community groups. “Aurora was delighted to provide support to Raptor Refuge and its founder Craig Webb and in the conservation of Tasmania’s magnificent raptor species,’’ Dr Davis said. “Aurora has supported Craig and his network of volunteers for more than 10 years, supplying and erecting poles for the aviaries on site. “Our latest $10k investment in the Education Centre will demonstrate the measures we take to minimise our impact on iconic species such as the wedge-tailed eagle, Australia’s largest bird of prey.’’ Aurora has installed a sign and a display of bird protection measures at the Refuge. These include safe, wooden perching platforms for the top of its power poles, insulation of bare wires and bird diverters, or ‘flappers’, which act as visual deterrents on powerlines for birds. The Education Centre features one-way glass to enable visitors to view the birds without causing them stress and the visitor experience will soon be enhanced with live-streaming video. “With more than 20,000km of powerlines and 220,000 power poles to manage around the State, it is impossible for Aurora to prevent all danger to birds. However, we are serious about wildlife conservation and particularly minimising risk for protected species such

as the wedge-tailed eagle, white-bellied sea eagle, peregrine falcon, southern boobook owl, swamp harrier, grey goshawk and masked owl,’’ Dr Davis said.

Above: Pictured with Public Officer Craig Webb are students from Sacred Heart Primary School, Geeveston. The bird that Craig is showing the children is an Australian Hobby

Australian and Russian electricity relations are sparked into life A 12-strong delegation from Russia’s National Energy Market Council has met with TransGrid officials, exchanging ideas about how to best meet the challenges facing electricity industries currently and into the future. During a two-hour meeting the delegates discussed everything from pricing to regulation models, as well as demand forecasting and what the electricity industry might look like in years to come. “A lot of the challenges currently being faced by networks and distributors in Australia, whether it be around cost, demand or regulation, are also being tackled by Russia at the moment,” said Maxim Mulyukin, a director with Russia’s Federal Tariff Service.

Russian officials stated that its electricity market was based on the Australian model, when it was brought in just over 10 years ago. They have returned to study how the National Electricity Market is now operated and regulated. The delegation was briefed by TransGrid’s Regulation and Business Improvement Manager, Anthony Englund and Operations Technical Support Manager, Jahan Peiris. “It was certainly an enlightening meeting – and our visitors were very interested about a range of topics including the design of our regulatory system, the governance arrangements, where competition starts in the industry and the important role of consumers,” Mr Englund said.

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Above: Maxim Mulyukin (smiling) who is the Director for the Federal Tariff Service in Russia Among the Russian energy industry stakeholder group were representatives of the market regulator (NP Market Council), the power exchange (JSC TSA), the system operator and industry regulator (Federal Tariff Service). “They were also quite keen to know more the penetration of smart grids and the establishing and enforcing of technical standards,” Mr Peiris added. TransGrid plans, develops and manages the NSW high voltage electricity network transmitting power between generators, bulk distributor corporations, some direct customers and other states to ensure a safe, reliable, efficient and secure supply to all business and domestic consumers in NSW and parts of the ACT.

Australian Power & Energy News - Page 3

New Dawn for iconic Snowy Mountains Scheme

Although the word ‘iconic’ is perhaps over used there is no doubt whatsoever that the Snowy Mountains Scheme is a genuine Australian icon. It’s also regarded by many as a superb example of engineering excellence and considered to be one of the greatest engineering feats of the 20th century.

HE SCHEME is one of the most complex multi-purpose, multi-reservoir hydro schemes in the world and has received much acclaim internationally. In 1967 the Snowy Mountains Scheme was rated by the American Society of Civil Engineers as one of the seven civil engineering wonders of the modern world. At the time the Scheme was a response to the nation’s energy and water needs, designed and built when sensibly, we relied on engineers to solve our nation’s infrastructure problems. In today’s climate such a solution may not have seen the light of day no doubt stalled, bogged down by endless academic debate. Fortunately, the Snowy Mountains Scheme, the largest engineering project ever undertaken in Australia, was completed in 1974. Although it took 25 years to construct, remarkably for such a huge, long term project, it was built on time and within the $820 million budget. These days you wouldn’t get much of a road constructed for that kind of money. More recently, independent technical reviews have confirmed that due to the rigorous design and construction process, combined with above average operational and maintenance practices, the ingenuity and performance of the Scheme is of world class standard. Snowy Hydro Limited, owns, operates and maintains the Snowy Mountains Scheme and this valuable asset couldn’t be in safer or more experienced hands. Snowy Hydro is a corporatised entity which has been highly active throughout the national energy sector and has an excellent and proven track record in engineering innovation, workplace culture, business practices and finance. The corporation employs around 650 personnel located in Cooma, Jindabyne, Talbingo, Khancoban, Cabramurra, La Trobe Valley, Sydney and Melbourne. It also provides insurance for other participants within the National Electricity Market as well as providing a broad range of financial products.

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Its management expertise within the energy sector is extensive. Apart from the Snowy Mountains Scheme, Snowy Hydro also owns and operates two gas-fired power stations in Victoria namely, the 300MW Valley Power and 320MW Laverton North power stations. Snowy Hydro is also the parent company of Red Energy, a retailer selling electricity and gas to consumers in the Victorian, South Australian and New South Wales markets. The Snowy Mountains Scheme is its most valued asset and Snowy Hydro’s priority is to ensure that the Scheme functions efficiently and continues to fulfill the expanding demands on its water and energy resources. Maximising the value and return on every dollar invested is also paramount. Currently, $400 million is being invested by Snowy Hydro Limited to modernise the facility to ensure even greater operational efficiency and to generate an increased energy supply to meet the needs of a growing population well into the future.

In the beginning there was a problem looking for a Solution Back in the 1880’s there was much discussion in Australia about the dire consequences of drought and how they could be minimised. One of the concepts raised at the time was to divert water from various rivers including the Murray, Murrumbidgee, Snowy and Tumut Rivers. However, it wasn’t until 1944 that a committee, featuring Commonwealth and State representatives, was formed to look at the bigger national picture. In particular, to determine how the water resources in the Snowy Mountains could be sustained and developed to offset the ravages of drought and to support the irrigation needs of farmers in the states surrounding the mountains. The result of that enquiry was the passage of ‘The Snowy Mountains Hydro-electric Power Act 1949’ on July 7 1949 legislated

by the Commonwealth Parliament. This established the Snowy Mountains Hydroelectric Authority which became the body responsible for implementing the Snowy Mountains Scheme. Construction of the Snowy Mountains Scheme commenced on October 17th 1949. The launch was highlighted by the then Governor-General, Sir William McKell, Prime Minister Ben Chifley and William Hudson when the first construction blast was fired at Adaminaby. Apart from providing a solution for water and energy needs, the construction process itself helped to build our nation. A shortage of workers at the time meant that foreign workers needed to be imported and over 100,000 migrants came from around 30 European countries specifically to work on the scheme’s construction. At the time, while some were able to bring their families, most were fathers who had left their wives and children behind in the home

country. However, the Scheme provided work which was unavailable in post-war Europe and the relatively high wages meant that fathers could save enough money to ultimately bring their families to Australia. Overall, around 70% of those who worked on construction of the Scheme were migrants and for them it was not only the beginning of a new adventure but a new life in Australia. But it was a harsh existence living and working in the Snowy Mountains. Most of the work was conducted underground, tunneling through solid granite rock in wet and cold conditions. The camps and towns built to house the workers were not ideal in the freezing temperatures that often prevailed. Tap water was often unavailable remaining frozen in the pipes. Add to that language difﬁculties as well as adapting to the nuances of life in a new country and working on ‘the Snowy’ meant that enduring hardship was the order of most days. But new life-long friendships were forged and a strong community spirit made life in the Snowy Mountains a little easier to bear. At the end of the day, for migrants working on the Scheme, it was the opportunity they desperately needed. For them it was the beginning of a new and better life and they were able to leave behind the ravages and poverty of post war Europe. For Australia construction of the Snowy Mountains Scheme and its associated mix of ‘new Australians’ reinvigorated our nation and broadened our culture and prosperity. It was truly a nation builder and undoubtedly, a successful response to a problem looking for a solution.

The Magniﬁcent Snowy Solution The legacy left by those who participated in the construction of the Snowy Mountains Scheme is a much needed hydro-electric facility which is simply magniﬁcent. The Snowy Mountains Scheme features 16 major dams, 7 power stations plus 2 more recent smaller stations, a pumping station and 225 kilometres of tunnels, pipelines and aqueducts. What is extraordinary is that the Scheme stretches across 5,124 square

New Dawn for iconic Snowy Mountains Scheme kilometres in the Kosciuszko National Park, a mountainous area in southern New South Wales, yet only 2% of all the structures are visible above the ground. Interestingly, during the 25 year construction period, the Scheme employed Australia’s first transistorised computer and it was one of the first to be used in the world. Referred to as ‘Snowcom’ the computer was used from 1960 to 1967 and played a pivotal role in ensuring both operational efficiency as well as various aspects of the construction process. Bear in mind, that in the sixties the commercial use of computer technology was uncommon and it would be at least 20 years before the advent of personal computers. That construction process also pioneered a number of important and innovative advances in engineering including rockbolting and the use of 330kV transmission lines. Although on completion there was some local environmental impact which is now monitored and managed, as a renewable source of energy the Scheme was also ahead of its time. The nations ongoing need for constant base load power is paramount and apart from renewable hydro and in the absence of nuclear power, solar and wind do not provide the consistency or volume of energy required to power the nation. The Snowy Mountains Scheme’s carbon footprint is minimal when compared to normal coal fired energy resources as it displaces approximately 4,500,000 tonnes of carbon dioxide emissions every year. It is without doubt a fairly clean and efficient source of renewable energy. Apart from the critical role the Scheme performs in ensuring the welfare of our domestic and business lives through the production of electricity, it also harnesses and protects our other most valuable resource. In simple terms, prior to the Scheme’s completion, melting snow and rain in the mountains would normally flow east to the coast and be wasted. The Scheme now collects that water and stores it in the lakes and reservoirs controlled by the dams. The Scheme then diverts the collected water through its trans-mountain tunnels and pipelines to the power stations lower down the mountains. When it has passed through the power stations, the water is then released back into the Murray and Murrumbidgee Rivers for irrigation further afield. The mountains provide an ideal location because cold temperatures mean less water evaporation and the height of the mountains provide the steep fall that is required to spin the power station turbines to create renewable hydro-electricity.

The Scheme is a complex piece of infrastructure but when combined provides around 32% of all renewable energy required for the eastern mainland electricity grid. It also provides a fast response power supply for the morning and evening peak energy demands in Sydney, Brisbane, Canberra, Melbourne and Adelaide. The Scheme also makes a significant contribution to the growth of the national economy by diverting water to farming areas and in fact the Scheme underwrites over $3 billion in agricultural production. It’s important to recognise that the benefits are achieved by infrastructure designed and built in the sixties, long before climate change became a hot topic. As a practical response to today’s search for cleaner energy, the Scheme has no equal in Australia. When built, it was certainly ahead of its time as it contributes to drought proofing the nation and importantly, producing much needed, clean renewable energy. Snowy Hydro Limited is currently enhancing and expanding those benefits to ensure that the Scheme remains a relevant source of energy for future generations and continues to operate with minimal environmental impact.

$400 Million modernisation to meet Future Demand In the 40 years since the Scheme was completed much has changed in the world as we know it. Although in the sixties the use of the ‘Snowcom’ computer was ahead of its time it is now seemingly primitive in comparison to the technology available today. Over the years since Snowcom’s demise in 1967, the Scheme’s control and management systems have been constantly upgraded but we are now well and truly in the digital age in which huge technological advancements have been made and which have the capacity to make management, control and output far more efﬁcient. With this in mind, Snowy Hydro Limited has embarked on a substantial modernisation programme which is current and ongoing until 2024. Comprehensive enhancements are being applied throughout the Scheme’s existing infrastructure to maximise the value of the Snowy Mountains hydro-generation assets. The modernisation process will greatly enhance the entire Scheme with the introduction of state of the art control room and protection systems to improve efﬁciency and management oversight. The Scheme’s series of power stations will be boosted dramatically

with modern components to increase output and to reduce the current high maintenance requirements of ageing circuit breakers, high voltage transformers and associated cables. New turbine runners are also being installed to optimise generation capabilities and improve water utilisation.

Power Station upgrades for improved hydro delivery The modernisation of the Snowy Mountains Scheme commenced in 2006 and various upgrades have already been completed but the $400 million programme is ongoing. There are nine power stations within the scheme with a total generating capacity of 3950MW. On average they produce 4,500 gigawatt hours of clean renewable energy each year to meet peak power demand, although this is currently being increased due to the installation of various technological advancements across the whole scheme. The seven major power stations are Murray 1, Murray 2, Guthega, Blowering, Tumut 1, Tumut 2 and Tumut 3. Tumut 1 and 2 are both underground. Recently, two small hydro power stations have been constructed and are operating; Jindabyne Mini Hydro Power Station and Jounama Small Hydro Power Station. Water is supplied to the power stations

via the pumping station at Jindabyne which pumps water from Lake Jindabyne through the Jindabyne-Island Bend Tunnel to the Snowy-Geehi Tunnel at Island bend. There is also a pump storage facility at Tumut 3 Power Station which returns water to the Talbingo Reservoir. Jindabyne has two pump sets; a 25.4 MW synchronous centrifugal pump which can pump at a rate of 12.7 m3/sec in tandem with a 6.7 MW induction motor booster/lift pump which pumps 12.7m3/sec. Modernisation of the Jindabyne Pumping Station is complete with outdated control and protection methodology being replaced with far more modern digital systems. The new technology will provide greater efﬁciency and ensure that the station utilises the water it pumps in the most consistent and cost effective manner. The seven major power stations within the scheme will all beneﬁt from the upgrades however, back in 2003/4 Snowy Hydro installed special Cooling Water Micro-hydro Generators in Tumut 3 Power Station which is the Scheme’s largest power station. These 120kW generators replaced the pressure reducing valves on the cooling systems for each of the six generating units. This particular installation further reduced emissions and now saves around 3,137 tonnes of carbon dioxide per year when compared Continued page 6

Australian Power & Energy News - Page 5

Continued from page 5

to the equivalent coal fired power station emission. Of further benefit is the fact that these micro-hydro generators capture previously wasted renewable energy and reduces the noise made by the previous pressure reducing valves. The complete upgrade to Tumut 3 Power Station was completed in 2012. All six generators at Tumut 3 have been upgraded increasing the station’s generating capacity from 1500MW to 1650MW. However, in ideal conditions the station can deliver up to 1800MW. To achieve this 20% increase in output, new turbine runners were installed in each generator which provided an additional 50MW capacity but due to advances made in computerised fluid dynamics and modelling by Toshiba, efficiency was also enhanced by 3%. This clever technology provides a further increase in power output without the need to increase the amount of water flowing to and through the generators. The upgrades to the power stations are comprehensive and that increased power output could not be achieved at Tumut 3 without the installation of new digital control systems to replace the old fashioned electromechanical components. The new control system collects a variety of data including, water flows, pressures, temperatures and electrical quantities. This data is automatically analysed in real time so that the system ensures not only reliability but consistency and delivers maximum efficiency in power generation. Snowy Hydro commenced planning for this upgrade eleven years ago and care was taken in that process to ensure that any upgrade

would deliver the required outcome to enable the power station to meet future demands. The combination of new turbine runners, control systems and refurbishment of electrical and mechanical components at Tumut 3 cost just in excess of $80 million. Tumut 3 is also GreenPower accredited which is a national accreditation programme that sets stringent environmental and reporting standards for renewable energy products offered by electricity suppliers to households and businesses across Australia. Similar modernisation of Tumut 1 and Tumut 2 Power Stations located near Cabramurra is ongoing although the major work will not commence until 2014. Already the seven main generator transformers and associated 330kV cables at the underground Tumut 1 Power Station have been replaced and new turbine runners for the generators will arrive by the end of this year to be installed in 2014. The new turbine runners for the generators at Tumut 2 Power Station have now been delivered and the upgrades to Tumut 1 and 2 will include extensive mechanical and electrical replacement and the installation of new digital control systems Guthega Power Station, located at the headwaters of the Snowy River and which is the oldest of the seven power stations has also beneﬁted with similar upgrades to its two generators. Apart from the installation of new turbine runners, a new digital control system replaced the old and outdated electromechanical technology at the station. Initial upgrades were applied in the Murray region in 2008 when Unit 14 at Murray 2 Power Station was overhauled. In 2012 modernisation work commenced at Murray 1 Power Station near Khancoban

with the installation of new protection and control systems for generator Units 7 and 8 with similar upgrades currently underway on Units 9 and 10. It’s expected that those same control and protection upgrades will be applied to all the remaining units at Murray 1 to be completed by 2015. Modernisation of the 16 main generator transformers at Murray 1 has commenced and will continue with completion anticipated in 2017. New turbine runners are currently being manufactured for the 10 generating units and will be installed along with upgrades to the mechanical and electrical components in 2015. In 2009 the control, protection and excitation systems were replaced at Blowering Power Station to facilitate more cost effective and reliable remote operation. All 21 air-blast generator circuit breakers across the Scheme have now been replaced with far more reliable SF6 insulated breakers. These advanced new breakers will reduce maintenance requirements and improve reliability. In addition, all 11kV distribution circuit breakers across the Scheme have been replaced.

Mini green power hydro’s reduce emissions To increase the environmental water ﬂows to the Snowy River, Snowy Hydro Limited constructed a 1.1megawatt mini hydro power station at Jindabyne Dam. This power station is GreenPower accredited and will save a further 5,500 tonnes of carbon dioxide per year. This is the amount which would be emitted by a coal ﬁred power station producing the same output. Continued page 8

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Quality and machining on a large scale M

EDINA ENGINEERING are specialists in the provision of large-scale Computer Numerical Control (CNC) machining services to a wide variety of clients right across Australia, New Zealand, Asia and even as far aﬁeld as the USA. The company has grown to be a key supplier of components and purpose-built equipment to the power generation, hydro-electric, mining, steel, rail industries and other heavy industries with a requirement for precision machining and equipment manufacture. According to Business Development Manager Greg Bullen, the company was started by Gus Medina in a garage in Camperdown in 1974 and, in 2014, will be proudly celebrating forty years in the industry providing solutions to their ever-increasing portfolio of clients. Mr Bullen said that Medina Engineering has earned the trust of industry worldwide as a manufacturing partner with their passion for quality, service, their knowledge and expertise and state-of-the-art machinery which, combined, have consistently allowed them to deliver time-critical and cost-effective solutions to clients. Medina Engineering has been involved with the Snowy Hydro for several years now

through the supply of precision-machined components for the power generator’s annual overhauls. These components have been manufactured and supplied under tight delivery time-frames with promptness and top quality being the key requirements. The company has also completed the repair and rectiﬁcation of a wide range of items for Snowy Hydro as required and regard the major utility as one of their blue chip customers which keeps Medina Engineering staff on their toes and operating at peak efﬁciency. Medina Engineering is also involved in other areas of the power generation industry, supplying precision components machined from exotic steels, welded components and conveyor pulleys and undertaking the repair and/or overhaul of heavy-duty underground coal mining equipment for the power industry. Medina Engineering has also supplied mining components throughout Asia and Australia from the Pilbara in WA through to the Bowen Basin in Queensland and everywhere in between. The products supplied range from large couplings and gear boxes, through to large conveyor pulleys complete with lagging, and associated equipment. Fan Body on Nissan Borer

Continued page 8

Proudly associated with the Snowy Hydro Modernisation Scheme Supplier of Precision machined components and Special Purpose Equipment Large CNC Mills, CNC Vertical & Horizontal Lathes, Two large 4-axis CNC Horizontal Borers HBMs, and 5-axis Multi-tasking Machine – turning, milling, drilling in One Set Up For more information, visit our webpage: www.medinaeng.com.au

Think Quality, Think Medina

Proudly ISO9001 Certified

20 Wendlebury Road, Chipping Norton NSW 2170 P: 02 9755 2377 F: 02 9755 3185

www.medinaeng.com.au Australian Power & Energy News - Page 7

Quality and machining on a large scale

New Dawn for iconic Snowy Mountains Scheme Continued from page 6

In 2010 the construction of a second small hydro power station was completed at Jounama Dam and attached to the dam’s existing river conduit. It is a 14.4MW small hydro and creates renewable energy from the release of waters to Blowering Reservoir. The Jounama Small Hydro Power Station can generate enough energy to power 6,800 homes each year and is also Green Power accredited. Compared to an equivalent coal ﬁred power station, Jounama Small saves around 53,500 tonnes of carbon dioxide emissions each year.

Smart tunnel technology reduces maintenance and costs

Machined Impellor Continued from page 7

Since the early 1990’s, Medina Engineering has been actively involved in the Australian rail industry in a number of different areas. They manufacture from the smallest to largest components utilised in rolling stock applications – ranging from small screws to the complete machining of bogies and headstock frames and the reproﬁling of wheels and wheelsets. The company also has a strong presence in the crane and steel industries also manufactures and supplies complete production lines for a wide range of industries throughout the world. Medina Engineering was founded on an absolute commitment to quality and, for that reason, 2010 was a milestone year for them because they gained coveted ISO 9001 accreditation. This achievement has been followed-up with yearly quality audits with the last having been conducted by Bureau Veritas in October, 2013. Over the last 3 years Medina Engineering have invested in several new large CNC machines including CNC mills, vertical and horizontal CNC lathes, large CNC horizontal borers and machining centres. Their machinery line-up includes two large 4-axis CNC borers with tool changers and indexing tables capable of handling items up to 2.5x2.5x3.5m, two CNC machining centres up to 1.5x1m and lathes with a diameter up to 2.4m diameter with a 6m travel.

Pump Body on Soraluce Mill Page 8 - Australian Power & Energy News

Full details of the machines are available at their website www.medinaeng.com. au. The company has also expanded their fabrication capabilities to complement their machining services for manufacturing a diverse range of special purpose machinery and equipment required by their customers. Looking to the future, Medina Engineering recently ordered a new Mori Seki NTX 2000 5-axis Multi-tasking machine – 1.5m long between the two spindles up to 600mm in diameter and capable of turning, milling and drilling complex shapes such as impellors, crankshafts and helical gears. Most importantly, this machine can do all aspects of the job in one set-up. This means reduced lead times as there are no multiple set-ups on 2 to 3 machines to complete an item and that there is a reduction in component cost when compared to conventional machining. This machine will be arriving in Feb at Media Engineering in 2014. If you have any queries on Medina Engineering’s capabilities and how they can provide your organisation with quality manufacturing, contact: Greg Bullen Medina Engineering Business Development Manager Phone: +61 2 9755 2377 Mobile: 0408 461 281 Email greg@medinaeng.com.au

Even the complex and extensive transmountain tunnel systems which deliver the water from the lakes to the power station generators are undergoing major upgrades and maintenance. This work is important with innovative maintenance techniques engineered and applied to ensure a safer environment within the 13 tunnels and to reduce future maintenance requirements. Earlier this year the Snowy Hydro Board approved expenditure for the use of a hightech Unmanned Underwater Vehicle (UUV) to be used to inspect the six unlined tunnels. Basically there are two sections that govern the Scheme and they are connected by a series of tunnels, pipelines and aqueducts. The two sections are the northern Snowy-Tumut Development and the southern Snowy-Murray Development. The tunnels perform a critical role in connecting the two developments to the Scheme’s main regulating storage, Lake Eucumbene on the Eucumbene River. The combined length of the 13 tunnels within the scheme is 135km and there are two types of tunnels. Those lined with reinforced concrete and others which are unlined. These have been created using alternative construction techniques such as rockbolting, a method invented by engineers during the initial construction process. Normally, to inspect and assess the condition of the unlined tunnels, all the water has to be removed prior to an intensive physical inspection. This rigorous and time consuming maintenance procedure has previously been conducted at various intervals between 5 to 20 years. It is not only a very expensive exercise but should rock falls occur it can be dangerous for those involved in the inspection. The possibility of rock falls and subsequent deterioration in ventilation for inspectors is

exasperated by the removal of the water as it changes the pressure on the tunnel walls and can cause structural weakness. However, now there is no need for such a perilous undertaking or the removal of water with the introduction of an Unmanned Underwater Vehicle. The UUV is directed through the tunnels by remote control and the vehicle features advanced cameras, sonars and the latest sonar technology to collect data on the condition of the tunnel. It also provides a detailed profile of the entire wall circumference as it travels through the tunnel network. The UUV provides engineers with enough data to be able to make informed decisions about any maintenance that might be required without physically entering the tunnels. This kind of technology is essential so that the potential for tunnel failures in the form of blockages can be dramatically reduced without the risk to operational and worker safety. The consistent storage and supply of water both for the generators and the delivery of water further down the mountain is critical and the UUV provides a superb solution for the current and future operation of the Scheme. The Snowy Hydro Board believes in and subscribes to the term, ‘Continuous Improvement’ and the investment in advanced technology throughout the Scheme is a demonstration of that commitment. The use of the UUV alone, will not only create a much safer working environment but will result in multi-million dollar savings in the longer term and ensure the smooth flow of water through the tunnels to maximise both output and efficiency of hydro energy generation. The power station upgrades are in effect, a further investment in our nation as they will continue to reap benefits for many years to come. As the Snowy Mountains Scheme heads towards its 40th birthday it has well and truly earned its place in Australian history. It is a much cherished icon, reflecting a period in time when a remarkable feat of engineering helped to build our nation. Within its tunnels there would be undoubtedly many stories to tell by the thousands of migrants who found a new home in Australia and who left their mark during its 25 year construction process. The benefits of the Scheme are enormous as it continues to contribute to the economic growth and wellbeing of our nation both in its role as a provider of water and a much needed source of renewable energy.

Smooth running at Snowy Hydro with remetalled Alloy Bearings I

N THE QUEST for greater operational reliability with rotating machinery, the highly skilled team at Alloy Bearings may well be the energy sector’s best friend. It could be said that bearings make the world go round and certainly, as far as anything that rotates is concerned, it would be a rocky road without those critical internal components. It’s why the art of remetalling or babbitting, as it is otherwise known, is so valued in the refurbishment of damaged bearings. It’s also why Alloy Bearings is regarded as a leading specialist in whitemetal plain bearing technology; they are simply very good at what they do in ensuring that the working life of assets that rely on bearings can be cost effectively extended. It’s also the reason why the company’s expertise in remetalling is in constant demand in New Zealand, Australia, PNG, Fiji, Samoa and further afield. Alloy Bearings has built a solid reputation over the years for a much needed talent that is now attracting customers throughout the Asia-Pacific region. Although Alloy Bearings manufacture new bearings for a range of industry sectors including food processing, refineries, rail and marine, it’s their special expertise in whitemetal bearing remetalling technology that is second to none. Remetalling or babbitting is not a recent development. Babbitting is the term named after Isaac Babbitt who patented the process in America way back in 1863. Basically, it’s the use of softer bearing metals to bond chemically or mechanically to an existing harder metal.

According to Kerry Tupp, Business Unit Manager for Alloy Bearings, white metal, which incorporates tin alloys hardened and strengthened with copper and antimony, is the preferred choice nowadays. “Whitemetal bearings have considerable advantage. Under normal operating conditions they have a very long life, they allow large momentary overloads, are able to handle lubricant problems and if misalignment occurs they are able to conform and compensate. “Whitemetal plain bearing failure is seldom sudden or catastrophic. Typically the result is an increase in running clearances that can be easily detected by vibration analysis or an increase in temperature. This means that damage to expensive rotating equipment is avoided or minimized. Repair can then be carried out and the re-metalling of the bearing provides considerable advantages in cost and time without sacrificing performance.” The $400 million modernisation programme currently underway at the Snowy Mountains Scheme is all about improving operational efficiency and with 9 power stations generating hydro-energy, bearings are a critical turbine component to ensure that efficiency. Alloy Bearings began their successful relationship with Snowy Hydro Limited back in 2009 when the company remetalled the first set of bearings and they are now a preferred white metal bearing supplier. Steve Wallace, General Manager of Alloy Bearings emphasises that working with Snowy Hydro is not just about securing another customer.

“We enjoy working with Snowy Hydro as they are very thorough with a strong engineering base. As a major provider of renewable energy the Scheme provides our team with an opportunity to respond with solutions that will stand the test of time. “It’s an important challenge which we accept with enthusiasm as we have the confidence in our own ability to rise to any bearing challenge whether in the manufacture or remetalling of existing componentry. “The Snowy Mountains Scheme is an icon and we are proud to be associated with such a significant flagship enterprise that delivers so much clean, renewable energy for Australia.” The Alloy Bearings team remetalled a number of multiple sets of bearings for the Tumut 3 Power Station as part of the modernisation program. These included the main pump lower guide bearings at 9,000kg each, the turbine guide bearings at 4,000kg each, thrust pads at 5,000kg per set, and the upper and lower guide pads at 400kg and 600kg per set respectively. An impressive total of 86,000kg of bearings to date. Due to the beneficial properties of white metal refurbishment the process is expected to extend the life of each bearing significantly. Alloy Bearings is based in New Zealand and their relationship with Australia has been well established for some time. The company provides bearing remetalling services to a significant number of Australia’s major power stations. Other Australian companies here have also benefited from the unique expertise provided by the Alloy Bearings team.

Remetalled and machined Main Pump Lower Guide Bearing

Apart from the company’s ability to manufacture and refurbish bearings, the way that Alloy Bearings simpliﬁes access to its range of services makes it a highly attractive proposition for any Australian entity requiring assistance with bearings. As far as business in Australia is concerned Steve’s philosophy is simple and direct. “We are very focused on continuing our expansion into the Australian market and it doesn’t matter where your business is located in Australia. The team here would prefer that a client treats us like we are just next door. When a client contacts us about a bearing we arrange freight from their location, do the job and then return it. “We are ABN registered which allows us to take care of all Australian Customs requirements and invoices as if we were in Australia. We provide a door-to-door “Easy Freight” service, it’s that simple.” For more information about this dynamic New Zealand company and how it can save you money when dealing with a bearing problem visit: www.alloybearings.com

BEARING SERVICES FOR

POWER GENERATION. Alloy Bearings provides specialist plain bearing services to power stations throughout the Asia-Paciﬁc region and we are pleased to be associated with the Snowy Hydro Scheme Modernisation Project.

Our services include:

“A preferred supplier to Snowy Hydro”

Bearing upgrades and modernisation Full inspection and reporting Project management and freight handling Replacement and retrofit bearings Remetalling, machining and manufacturing

Visit us online at www.alloybearings.com or Free phone: 0800 423 9423 (NZ) 1800 REMETAL (736 3825) (Australia)

A L L OY B E AR I NG S Northgate Business Park, 22 Hood Street PO Box 161 • Wellsford 0940 • New Zealand Phone: +64 9 423 9423 • Facsimile: +64 9 423 9428 Alloy Bearings is accredited to ISO 9001:2008 Australian Power & Energy News - Page 9

™

machinemonitor enhances electric asset life cycle HE SNOWY MOUNTAINS Scheme’s $400 million modernisation programme currently underway has served to highlight a number of key contributors who are making a huge difference to the ongoing performance, efﬁciency and reliability of that now legendary, renewable energy facility. One of those making a difference is machinemonitor™, a NSW company which has developed a unique ability to make an entire electrical circuit, generator to driven equipment, and its associated componentry ‘visible’ from beginning to end. Managing Director, Mike Davis explains. “At machinemonitor™ we see ourselves as strategic partners in the life cycle management of electrical assets. Our role is to ensure that owners and operators can consistently maximise the value of their business through electrical asset performance. What is critical to maximising the performance of any piece of electrical equipment is its working condition at any given time. However, in the energy sector a particular electrical circuit can include a number of major components and they are all critical to the end result in terms of efﬁciency, performance and the desired output. So we have developed what we refer to as an ‘asset management toolkit’ which allows us to analyse the complete circuit and its components from the generator right through to transformers, switchgear, cables and the

Page 10 - Australian Power & Energy News

Mike Davis electrical machine at the end of the circuit. In effect, what we do is provide total visibility of those assets and their individual contribution to the total output. We can also determine their condition and the most cost effective way of extending the life cycle of each component to achieve ongoing reliability and maximum performance.” Of course, the correct interpretation of data is the key to securing maximum performance and the dedicated team at machinemonitor™ has a wealth of skill accumulated over decades and enough speciﬁc technical expertise to make that call. As Mike says, “It’s our knowledge of electrical machinery and our ability to take condition monitoring data to the next level that

gives us the edge. It is there that we translate that data into useful information that can be understood by plant operators and where it can be constructively implemented to make a positive difference.” The contribution to the modernisation of the Snowy Mountains Scheme made by machinemonitor™ was extensive and is ongoing. The company’s involvement to date included the supply and installation of upgraded partial discharge equipment to monitor the condition of stator winding insulation in the generators. This particular upgrade is typical of the overall approach taken by Snowy Hydro Limited in its efforts to modernise the facility, but being ‘ahead of the game’ has always been a feature of the Scheme. During the 25 year construction process, engineers ‘invented’ new construction techniques which have since been adopted worldwide. Prior to its completion in 1974, the Scheme had already utilised the ﬁrst computer programme in Australia called ‘Snowcom’. Early in its working life the Scheme employed early Partial Discharge technology using cable couplers for monitoring which, in their day, was considered state of the art. The machinemonitor™ team replaced the old fashioned couplers with modern epoxy mica couplers and also installed continuous monitors to allow monitoring of Partial Discharge activity 24 hours a day.

The replacement of the couplers by machinemonitor™ presented a unique challenge. The team had to remove the existing cable type couplers from the generator windings without inflicting damage on the winding. Working alongside Electrical Engineers from Snowy Hydro, the experienced machinemonitor™ team developed a procedure which allowed the removal and replacement of the couplers without affecting the condition of the windings. machinemonitor™ also calibrated the monitoring system for signal delay times and installed interfacing monitors into the LAN/WAN to facilitate continuous remote monitoring of the generator stator windings. The team was assisted initially by a specialist from IRIS, a Canadian company which was the original manufacturer of the Partial Discharge equipment and who had relevant expertise in this particular type of calibration. The end result proved to be extremely successful providing greater visibility of partial discharge activity in the stator windings and with more timely monitoring responses ensuring greater reliability in data collection. As an independent consultancy, machinemonitor™ has offices across Australia in New South Wales, Queensland, Northern Territory and Western Australia and in Auckland, New Zealand and specialises in life cycle management of electrical rotating machines and fixed electrical assets. The

company’s range of services include design, troubleshooting, ﬁeld testing, repair, condition monitoring and strategic management of electrical assets. The company provides a unique range of services and it’s no surprise that there is a growing demand for their specialised skill set both in Australia and internationally, particularly in the greater Asia Paciﬁc region.

Kawerau, a Case Study in the benefits of Life Cycle Management As an example of the benefits of machinemonitor™ expertise in life cycle management, Carter Holt Harvey (CHH) is one of Australasia’s largest pulp and paper producers and the company was concerned about the reliability of their primary and secondary refiners at their Kawerau plant. The refiners are used to process pulp and are driven continuously every day by powerful, 11kV Siemens Synchronous Motors. Obviously, the motors are critical to the health and wealth of that enterprise and reliability and efficiency is a key issue. Although the company had been conducting monitoring to some extent, the true condition of the motors was not clear. In any event, sourcing a spare motor was not only expensive at around NZ$760,000 but would require a 48 week turnaround due to manufacture and importation from Germany. Following consultation with CHH, machinemonitor™ applied its ‘asset management toolkit’ which accurately assessed the condition of the motors. Once the true risk of failure was established, machinemonitor™ quickly developed a strategic plan for recovery in the event of that potential failure to minimise any downtime which would be detrimental to the refinery’s economic welfare.

Of course, for-armed is to be for-warned and the machinemonitor™ team put in place a monitoring and testing programme which included mechanical vibration testing (mechanical anomalies), annual visual inspections (general machine condition) and six monthly on-line partial discharge testing (insulation condition). These results were then analysed against standard exception/rejection criteria and in the case of partial discharge test results, benchmarked against databases of similar machines. In effect, machinemonitor™ was able to save or, at least delay the need for the huge ﬁnancial investment in a spare motor by establishing that the risk of motor failure was in reality low. By improving motor reliability it also meant that any potential risk was reduced and acceptable. This was also on the basis that with ongoing risk management and testing strategies the true condition of the motors would always be evident. When coupled with a fall-back recovery plan should it be needed in the future, Carter Holt Harvey could relax in the knowledge that the health and wealth of its enterprise was secured well into the future.

water and energy as well as chemical resources and defence. There is no illusion as far as machinemonitor™’s electric capability is concerned, with a hands-on team that can make visible what otherwise cannot always be seen. One thing’s for sure; this is a company that can save money in operating expenses for other companies and for that reason alone, we will be hearing a lot more about machinemonitor™. Visit: www.machinemonitor.com for more information about machinemonitor™. Right: HydroTrac Continuous monitor module (Tumut 3 PS) Below: Guthega Generator Hall

The solution to Risk Management of Electric Assets Whether minimising environmental impact by improving electric motor efficiency or maximising business potential by identifying risk to electric assets and improving reliability, machinemonitor™ do provide a highly qualified solution. The company’s operational reach and influence extends throughout most sectors of our industrial and manufacturing economy with a client list that features companies that operate in oil and gas, mining and minerals,

Australian Power & Energy News - Page 11

Toshiba Your

Reliable Partner in the

Power Industry

Here at Toshiba International Corporation we are proud to be associated with the modernisation of the iconic Snowy Mountains Scheme. Toshiba is a world leader in single-stage pump turbines, high head Francis turbines and high speed generators. Our hydro product range includes, small and large hydro turbines, generators, control systems, governors and excitation systems.

Page 12 - Australian Power & Energy News

Innovation is at the heart of everything we do at Toshiba in the energy sector. Our research and development programme is designed to improve efďŹ ciency, performance and reliability in all components that we design and manufacture and the results speak for themselves. We are pleased to be the preferred supplier of turbine runners and associated components for the Snowy Hydro facility.

In any project relationship, flexibility is the key to success. At Toshiba International Corporation we approach every project as a partner would. Our role is to provide every assistance for our client, to be flexible from start to finish so that we can ensure that any new or unexpected challenge can be overcome and that the benefits of the project are, not only met, but optimised at every level. Apart from our contribution to the modernisation of the Snowy Mountains Scheme, Toshiba has recently successfully commissioned the largest new hydro

development in the southern hemisphere, the Bogong Power Station. In New Zealand we have successfully uprated the hydro turbines at Aviemore, Benmore, and Ohakuri Power Stations. Since, its inception in Australia in 1978, Toshiba has installed over 15,000 MW of generation capacity and over 12,000 MVA of transformer capacity. Whether it’s in transmission and distribution, construction, engineering, thermal or geothermal power or hydro-electric energy, Toshiba will always provide ﬂexibility with the power of initiative and innovation.

Toshiba International Corporation Pty Ltd 2 Morton Street Parramatta NSW 2150 Tel: +61 2 9768 6600 Fax: +61 2 9890 7546

Australian Power & Energy News - Page 13

Toshiba. Power for the 21st Century

N AUSTRALIA’S drive towards increasing cleaner, renewable energy resources, the team at Toshiba International Corporation are constantly developing new and better ways to assist that sector in the way renewable energy is harnessed. However, it’s nothing new for this global power-house, Toshiba has been highly proactive in the Australian energy sector for the last 35 years and the company’s recent presence in the Snowy Mountains was all about power; renewable hydro-electric power to be precise. There are seven major power stations at the heart of the Snowy Mountains Scheme and Snowy Hydro Limited is investing $400 million in a modernisation programme to improve efficiency and increase output to meet the demands of a growing nation. So who better to contribute to a performance upgrade than the masters of innovation? Toshiba International’s relationship with Snowy Hydro dates back to 2003 when the company was involved in the upgrade to Murray 2 Power Station and were later contracted to upgrade Tumut 3. Tapan Paul, Toshiba’s Project Manager, of Hydro Power Systems & Services, explains how the relationship has continued to prosper. “Our relationship with Snowy Hydro Limited is built on mutual trust and confidence, established over a period of time. The initial opportunity to be involved was a result of a competitive tender process and following our initial success with the first project at Murray 2 and later at Tumut 3, we secured another three projects at Guthega Power Station as well as Tumut 1 and Tumut 2. “We approach every project as a partner would and in the execution of any project our role is to provide flexibility for our client to ensure that all the project benefits can be not only achieved but optimised. “We have the utmost confidence in our technology and the scope of our product range allows us to meet those demands. We particularly enjoy our relationship with Snowy Hydro and look forward to it continuing into the future.” Over the years Toshiba International has concentrated much of its own research and development energy on advancing the efficiency of hydro-electric power generation. Bear in mind that Toshiba was established in 1875, so within its walls and corridors there is a wealth of knowledge and skill supported by a corporate history featuring extraordinary innovation and success. Toshiba is also a world leader in single-stage pump turbines, high head Francis turbines and high speed generators. Its broad product range includes Francis, Kaplan and small hydro turbines, control systems, governors

Murray 1 Model test Witness by Snowy

Murray 1 Model Dimension Check Witness by Snowy

and excitation systems. Given this well-established background, it makes Toshiba the ideal source for improving the efficiency and performance of any hydro facility such as the iconic Snowy Mountains Scheme. Broadly speaking, Toshiba was involved in the uprating of six power stations within the Scheme but the scope of works varied depending on the needs of each power station. The company’s contribution was challenging to say the least because in order to optimise the performance of each power station, the type and rating of any existing original equipment (OEM) had to be replaced or combined where appropriate. Subsequently, the upgrade of each power station was in effect, an exercise in Toshiba flexibility and in meeting that challenge it revealed the company’s capacity to optimise the desired benefits of the overall project. In general, although there were variables at each power station, the Toshiba team designed, manufactured and delivered turbine runners, guide vanes, runner and fixed seals, face plates, extensions to stay vanes, main shaft gland housing, coupling equipment and other associated components. The team also conducted water to wire study and model testing to ensure optimisation would be achieved when the new componentry was installed. However, to extract the optimum performance from each power station, further challenges had to be overcome. These were due to pre-existing issues such as turbine vibrations, airborne noise, cavitation, runner cracking and inherent deterioration in efficiency. In order to combat these issues, the Toshiba team conducted Computational Fluid Dynamics (CFD) to determine the root cause of these issues so that in conjunction with Snowy Hydro, Toshiba

Tumut 2 Runner Final Inspection Witness by Snowy could design the runners and other components in such a way as to either eliminate or minimise these problems. Significantly, Toshiba’s expertise in analysing the results of the CFD application and in the design process that followed, provided further performance enhancement over and above the initial expectations. As an example, the largest power station in the Scheme is Tumut 3 and its six generators were upgraded by Toshiba in 2012. This increased the power station’s generating capacity from 1500 megawatts to 1650 megawatts and under ideal conditions Tumut 3 can now deliver up to 1800 megawatts. Overall, the upgrade represents a 20% increase in generating capacity and to achieve this Toshiba supplied new turbine runners which provided an additional 50 megawatt capacity for each generator. However, due to Toshiba’s analysis of the computerised fluid dynamics and with further modelling, Toshiba enhanced that new level of efficiency by a further 3%. This new technology is typical Toshiba innovation at work, because the further increase in generating capacity is achieved without the need to proportionally increase the amount of water flowing to and through the turbines. There is also a pump storage facility at Tumut 3 Power Station which returns water to the Talbingo Reservoir and Toshiba were involved in modernising the Tumut 3 pump-turbine. The upgrade allows the turbine to either generate

Page 14 - Australian Power & Energy News

power or pump water for storage. This means that during off-peak periods, when consumer demand is low, water can be pumped for storage and in peak hour periods, as demand increases, it can be used to generate power. Much like the endless hours that go into improving the aerodynamic qualities of a Formula One racing car, Toshiba has invested heavily with both time and money to optimise the efﬁciency of its range of turbine runners. The company’s research and development programme has been running for many years researching, modelling and testing all aspects of ‘runner technology’ including design, material composition, performance and reliability. Toshiba International’s Business Development Manager, Gary Byak is therefore understandably proud of his company’s achievements. As he says; “We believe that we lead the way in turbine runner technology and as a result, Toshiba International has the largest installed capacity of thermal and hydro turbines in Australia. In New South Wales alone, we have 8,000MW thermal turbines and 4,000MW of uprated hydro turbines installed. “From our Parramatta headquarters we’ve spent over 35 years establishing our business model in Australia and New Zealand and they are both very important markets. It’s why I am extremely proud and delighted that Snow Hydro Limited made Toshiba the supplier of choice in the supply of all the turbine runners required for the modernisation of the iconic Snowy Mountains Scheme.” Toshiba International is also responsible for the supply of components and commissioning of Bogong Power Station which is one of the largest and recent hydro developments in Australia. The company has also contributed to the hydro plant at Wivenhoe Power Station for Tarong Energy (Now owned by CS Energy). It’s pleasing to note that in an age when the pursuit of constant base load, renewable energy resources is paramount, not only is the Snowy Mountains Scheme rising to meet the demands of tomorrow’s cleaner world, but companies like Toshiba International Corporation continue to reach into the future; creating new and advanced technology that will provide better and more efﬁcient solutions to improve how that much needed energy is harnessed.

Developing sustainable power grids, with Alstom ELECTRICAL GRID ENGINEERING Alstom builds power grids for now and the future. We interconnect major grids, ensure an intelligent balance between production and consumption, and improve the integration of renewable energy.

www.alstom.com

Australian Power & Energy News - Page 15

Alstom transforms Tumut 1 for Snowy Hydro HE REMOTE township of Cabramurra in New South Wales is the highest permanently inhabited town on the Australian continent and was originally created to house workers involved in the construction of the Snowy Mountains Scheme. Itâ&#x20AC;&#x2122;s located 1,488 metres above sea level and has a population of around 60 residents, some of which are currently employed by the Scheme. The town is also a tourist attraction, not just because of the crucial role it played in the Schemeâ&#x20AC;&#x2122;s 25 year construction process which was completed in 1974, but also because of its proximity to Tumut 1 Power Station. Tumut 1 is an underground power station and one of the Snowy Mountains Schemeâ&#x20AC;&#x2122;s seven major power stations. It operates from 366 metres below ground level and is just 3 kilometres south east of Cabramurra. Tumut 1 commenced operation in 1959 and now has seven transformers and four turbine generators with a hydro-electric generating capacity of 330 megawatts. Interestingly, the original transformer at Tumut 1 weighed 81.2 tonnes and each rotator weighed more than 203 tonnes. Such was its size and weight that it had to be delivered in sections for assembly on site. Snowy Hydro Limited owns, operates and maintains the iconic Snowy Mountains Scheme and in 2006 embarked on a $400 million modernisation programme. The programme is extremely comprehensive and upgrades will be applied to most of the componentry and control systems throughout the Scheme. Such is the extent of the modernisation that, although many projects have been completed, the programme will continue until 2024. The purpose of the modernisation is to improve efficiency and performance of the Scheme in order to meet the growing demand for clean, renewable hydroelectricity well into the future. One of the projects was to upgrade Tumut 1 and Alstom was awarded the contract to design, manufacture and install seven 90 MVA single phase transformers to replace the existing ACEC Charleroi 56 MVA units. In completing the Tumut 1 project the Alstom team faced many challenges. Replacing old technology with new in itself is a challenge, not least due to the

Page 16 - Australian Power & Energy News

existing limited space as well as associated componentry, wiring and control systems that need to be considered. So from the design stages, the logistics and the final installation of seven transformers, the experienced Alstom team were tested. Work commenced in November 2011 and the Alstom team had to contend with the logistics of overcoming access via the undulating, winding mountainous roads and the various extremes of weather that prevailed throughout the installation process. However, despite the elements and unique location the replacement transformers were successfully delivered and once removed, the old transformers were taken back down the mountain to be recycled. The installation of the new transformers introduced its own set of challenges. Simultaneously, various aspects associated with the replacement process were executed

and they were co-dependent onn each other. For instance, duringg the transformer change-over thee 33kV cable was being replacedd and major modification to thee LV bus structure was also beingg conducted. The multiple tasks required to complete the installation off seven new transformers and the added complication of working within a limited space required co-ordination. It is to the credit of all involved that the process was completed without incident. Just over eighteen months since the commencement of the project the final transformer was installed by Alstom and energised on the 17th June 2013.

CHIRNSIDE CHIRNSIDE PARK PARK FEATURE FEATURE

SP AusNet Meets Growing Demand in Chirnside Region L

IKE most capital cities, Melbourne continues to expand outwards in the city’s efforts to accommodate the ever increasing range of infrastructure, business and residential needs. Chirnside Park, named after Thomas Chirnside, who founded the Chirnside stud herd empire in 1839, is located 33 kilometres north east of the Melbourne CBD, in a region which has typically experienced a steady growth in population over the past ten years.

It’s one of the reasons why SP AusNet is currently investing around one billion dollars in capital works projects to meet that growing demand throughout its gas and electricity networks. The company already manages a $7 billion electricity and gas network providing energy to over 1.2 million customers in south east Australia and Chirnside Park is one of the beneficiaries of that huge investment. SP AusNet’s commitment to the region is clearly demonstrated in the construction of the new Chirnside Park Zone Substation and when completed in 2014 it will deliver a secure and reliable power supply to allow for both current and anticipated growth into the future. In particular, the new zone substation, located in Fletcher Road in Chirnside Park, will enhance the capacity of Melbourne’s electrical infrastructure. Allowing SP AusNet to meet the peak summer period demand and protect the commercial and residential community from blackouts that can have a negative effect on the local economy and diminish the quality of lifestyle enjoyed in the region. The 3,683 square metre site was purchased by SP AusNet specifically for that purpose and the zone substation will also service Lilydale, Croydon North, Mooroolbark and the general Shire of Yarra Ranges area. A number of new developments are also in the planning stages including major commercial and residential estates, as well as the expansion of the Chirnside Park Shopping Centre which requires a load increase of 3MVA in 2014. In simple terms the new zone substation will convert the available network 66kV electricity supply down to 22kV so that it can be then made available for distribution to consumers. In part, this will require the installation of new 66kV and 22kV power lines both underground and overhead on Fletcher Road, Kimberley Drive and the Maroondah Highway. Existing power lines through Chirnside Park, Croydon and Ringwood North will also be upgraded to cater for the supply changes. The range of technical equipment to be installed includes a 66kV outdoor ring bus with 5 initial 66kV circuit breakers; two new 20/33 MVA, 66/22kV transformers; two indoor 22kV switchboard modules; six new 22kV feeders including associated distribution line works; 2 X 6 MVar capacitor banks and a Neutral Earthing Resistor.

Above: Proposed Feeder Configurations of CPK Feeders The new zone substation will also feature new control and amenities buildings and require a 66kV line between Ringwood Terminal Station (RWTS), Ringwood North (RWN) and Chirnside Park (CPK). This will include 600 metres of 66kV cable at the CPK end and 700 metres of new overhead 66kV line in Oban Rd at the RWN end. There will also be a new protection scheme implemented for the RWTS-RWN/CPK 66kV line as well as upgrading of the Supervisory Control and Data Acquisition (SCADA) and Distribution Feeder Automation DFA). Standard network upgrade works for a new zone substation will be conducted such as AMPACTING, surge diverters and distribution transformer, tap setting changes. One of the challenges faced by the team was in combatting deration of the 66kV underground

Above: Delivery and Encllosire of New Transformers

cable due to very poor thermal resistivity in the surrounding soil. So during installation rock excavation was conducted prior to backfilling the cable conduit with new soil that had good thermal resistivity properties. SP AusNet’s 78 member, construction and commissioning team is formidable and highly skilled in sub-transmission and distribution network automation. Another 20 personnel including the project manager, engineers and others who worked on the planning as well as the technical and architectural design of the substation. SP AusNet’s Design and Architecture team were conscious of the need to minimise the environmental impact of the new substation and to reduce its visual impact in the surrounding neighbourhood. With that in mind the new Chirnside Park Zone Substation is designed to

be as inconspicuous as possible and to blend in with the neighbouring structures. For that reason a new architectural fence will also be installed on Fletcher Road to compliment the streetscape and also control views into the substation. The fence will comprise of a series of pre-cast concrete panels with a ‘rippled’ pattern and perforated mesh screens. These concrete and mesh materials have been selected because of their durability and interesting tactile features. The new Chirnside Park Zone Substation is an example of the proactive approach taken by SP AusNet to ensure that wherever possible it can meet the demands of a growing consumer base well into the future. For more information about SP AusNet and other projects visit; www.sp-ausnet.com.au

Above: New Transformers Australian Power & Energy News - Page 17

CHIRNSIDE CHIRNSIDE PARK PARK FEATURE FEATURE

Zinfra Continues to Deliver on Greenfield Substations EADING infrastructure service provider, Zinfra, is the principal contractor responsible for the construction, testing and commissioning of the new greenfield Chirnside Park zone substation. This project is being delivered for SP AusNet. Zinfra has recently delivered similar greenfield substation projects for SP AusNet in Kalkallo, Lysterfield and South Morang. Significant growth in the Chirnside Park area has created the need for a new zone substation. Increasing power load to the area will support commercial and residential demand, especially in peak periods such as summer, and reduce the incidence of blackouts. The new Chirnside Park zone substation has been designed according to the modular concept and modified in several areas to suit site conditions. The substation, designed to ultimately house three transformers, will initially comprise:

Top: The Chirnside Park site

• • • • • • •

Three 66kV line entries Two 66/22kV transformers Two 22kV switchrooms Two 22kV capacitor banks A control building A Battery room A Puraceptor full retention separator, and • An amenities building. Zinfra will install all new underground and overhead 66kV and 22kV power lines on Fletcher Road, Kimberley Drive and the Maroondah Highway. Responsible for both the overhead and underground works, Zinfra’s Project Manager Daniel Agnew commented, “Having the capability to self-perform all these aspects of the job, means [Zinfra] can deliver efﬁciencies and improved safety management.” Mr Agnew went on to add, “Timing is critical for this project. Because Zinfra is the principal contractor, we are able to tightly control and manage this aspect of the project. So far, we’ve managed to deliver on or ahead of schedule.” Once the new infrastructure is installed, Zinfra will also undertake: • Commissioning of all primary and secondary equipment • Site compliance tests to prove the safe operation of the plant Page 18 - Australian Power & Energy News

Above: Daniel Agnew, Project Manager, Zinfra Right: The Zinfra crew, left to right: Chris Russell, Ryan Rule, Chris Slagter, Aaron Gibbs, Andrew Hawkins Below Right: Matt Mann and Henok Gebremariam, SP AusNet, inspect the newly installed transformer control cabinet

• Commissioning of the SCADA and Protection Signalling, and • Coordination with the SP AusNet on-site staff and with the SP AusNet control centre as required. The substation is in a high density location bounded by restaurants, a bowling alley, 7-11 and various other small businesses. Stakeholder management and consideration of these factors has been crucial to the project. Having commenced in April 2013, the project is notable for its seamless delivery to date. The extensive civil works were completed on time, the transformers installed ahead of time. The 66kV ring bus, circuit breakers and line entries are currently being installed. The substation construction is expected to be completed in March 2014.

Australian Power & Energy News - Page 19

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An innovative bid wins Zinfra contract with GippsTAFE N OCTOBER 2013, GippsTAFE and Zinfra Southern Contracting (Zinfra) signed a significant contract for the redevelopment of the Chadstone campus electricity training yard in Melbourne. GippsTAFE provides the majority of training for apprentices and trainees employed in the Victorian electricity distribution industry and is considered the preeminent training provider for electricity network owners and contractors in Victoria. Zinfra, a leading infrastructure service provider, recognises the importance of a strategic relationship with GippsTAFE and the benefits improved training facilities will provide to the wider industry. Howard Lewis, Senior Project Estimator, ensured Zinfra’s bid success when he applied his experience and knowledge to the tender. “I noticed when I looked at GippsTAFE’s drawings that the proposed plans were limited to one network and didn’t offer apprentices the network variety you get in real life,” he said. Howard, who actually trained at the GippsTAFE facility many years ago, was able to draw on this direct experience, as well as many years in the field in Australia and South Africa with the EThekwini Municipality (previously the Durban Electricity Department). What Howard suggested was “more of a sense of what the industry can offer and a number of different network configurations so apprentices can see what they’re going to see in the real world.”

Zinfra’s innovative proposal included: • The differing approaches of the Victorian electricity network owners, including a variety of kiosks, cable and overhead structure specifications. • A number of purposely “non-compliant” overhead and public lighting structures to enable apprentices and trainees to conduct inspection audits on structures with known defects to help ascertain and test their knowledge of applicable standards and specifications. • Substituting the out-dated public lighting lanterns with lanterns that are current standard for all Victorian networks. • A range of power and fibre optic cable sizes for training purposes.

Above: Howard Lewis, Senior Project Estimator, Zinfra Right (L to R): Howard Lewis; Neil Mathys, Project Manager, Zinfra; Mark Gould, General Manager Southern Contracting, Zinfra; Doug McRae, Training Coordinator Electrical, GippsTAFE; Carol Eliot, Executive Director Academic Programs, GippsTAFE; Jason Davis, Distribution Manager, Southern Contracting, Zinfra; Chris Connell, Manager, Market Development & Commercial, Southern Contracting, Zinfra Page 22 - Australian Power & Energy News

The upgrade of the existing high and low voltage overhead and underground training network includes replacement and reconﬁguration of: • • • •

Overhead structures and conductor Underground cables Transformers and switchgear Installation of communications conduits and fibre optic cables, and • Demolition of specified yard storage buildings. The works are expected to take eight weeks to complete and will be delivered by Project Manager, Neil Mathys, who was also a critical driver behind the initiatives to build the concept. This upgrade to the existing electrical network practical training facilities at GippsTAFE will mean their facilities will better reflect actual Victorian network configurations and improve the practical training they are able to provide to their apprentices and trainees. GippsTAFE Executive Director of Academic Programs, Carol Elliot, endorsed the value and importance of the project. “GippsTAFE is extremely pleased with the prospect of adding further value to the partnership with industry on the Energy and Telecommunications campus. We are proud to be working with an electrical network specialist with the expertise and innovation such as that of Zinfra, and we look forward to closely liaising with Neil and Howard during the redevelopment.” Carol emphasised how important the yard redevelopment was to presenting more reallife training scenarios to apprentices, and how, along with the recent completion of the site building construction work, the overall site facility presents state-of-the-art training opportunities for all electrical network stakeholders.

Above: Mark Gould and Carol Eliot Right: The GippsTAFE training yard to be updated at Chadstone

Making the Best of Testing Times

F there were gold medals awarded to those who operate with distinction in the world of testing and calibration and in particular, for those who are determined to be the best of the best, then Mobile Test ‘n Cal would be right up there. This award winning and highly accredited mobile testing company based in Queensland takes what it does very seriously. Mobile Test ‘n’ Cal’s fleet of service vans are state of the art and fully equipped to produce up to 210,000 volts safely which allow operators to test any piece of critical safety equipment on site. It includes anything from LV gloves rated at 500V to large elevated work platforms as well as cherry pickers or bucket trucks which may require testing up to 207kV. But what really separates Mobile Test ‘n Cal from their competitors is the level of training and support provided for their field personnel and it’s an ongoing disciplined process. The company even employs a highly qualified Technical Manager whose sole duty is to train field staff and provide instant advice whenever required by their mobile technicians. The high level training provided encompasses not just a full in-house intensive training package, but also includes ongoing tuition on the latest electrical instruments and safety equipment as well as ‘best practice’ work processes. Importantly, training includes not just theory but practical front line application covering everything that is learnt in the classroom. According to General Manager, Alex Loew the company’s philosophy is simple; “Our aim is to be the very best at what we do whenever and wherever we’re required so our whole training programme must be of the highest standard. Not only do our staff deserve that support but so do our clients. This is a safety issue and our clients need to know that when we test or calibrate their equipment that it will fulfil the task required with the utmost accuracy and their employees are never at risk due to faulty electrical equipment.” Apart from the Electrical Safety Regulation 2002 which states that, “it is mandatory for an Employer or Self Employed Person in the electrical industry to ensure the suitability of any safety equipment, test equipment or test instruments every 6 months”, it’s also a question of efficiency in the delivery of electrical energy. Operators in the electrical industry cannot afford to lose time or efficiency due to faulty equipment and whether it’s the accuracy and safety of equipment or concern for the potential loss of working hours, downtime can be costly. Mobile Test ‘n Cal not only makes it easy for clients to abide by regulations by providing an ‘onsite’ service but the onsite delivery of its services minimises or eliminates any down time due to service requirements. Mobile Test ‘n Cal also provides records of all testing and calibration for their clients to ensure that regulatory standards are always maintained and can be proven. Bear in mind that as per the Electrical Safety Regulation 2002; “Test Results for the Test Instruments must be kept for a minimum of 5 years. Failure to comply can result in a maximum of 40 Penalty Points.” These regulations and others cover the electrical industry and for the most part, are about maintaining safety and efficient workplace standards as well as ensuring a consistent, standardised output of electrical supply and associated equipment. It’s in maintaining those mandatory standards and equipment safety that Mobile Test ‘n’ Cal provides the complete service.

Tester

Mobile Test ‘n Cal is the preferred choice throughout the energy sector across South East Queensland, particularly testing and calibrating safety equipment and instruments at power stations. Elevated Work Platforms (EWP) are another speciality and Mobile Test ‘n Cal EWP services are always in demand. Recently, the company also opened a new branch in Townsville to cater for demand for its services in Queensland’s northern region and through franchise acquisition is continually spreading its operational coverage throughout Australia. Mobile Test ‘n’ Cal already provide the complete service package in Papua New Guinea through its branch office in Port Moresby. Mobile Test ‘n’ Cal’s approach to calibration is based on comparing an instrument designed to measure with the required test standard. However, the test equipment they use is NATA Traceable and provides the highest levels of accuracy in the industry. The calibration process itself produces detailed reports for clients on the tested equipment as per the specifications of that particular piece of equipment. In effect the comprehensive testing and calibration process reveals both the current state of the device and reveals whether there is any potential for faults to occur. Recently, Mobile Test ‘n Cal increased its range of services with the addition of Infrared Temperature Gun and Thermal Imaging Camera calibration. High Voltage testing is a particular benefit for Mobile Test ‘n ‘ Cal clients because apart from the mobile service minimising downtime, the company’s vans are equipped to test any piece of safety equipment such as gloves, mats and hotsticks. The ability to test insulation materials is a huge safety issue and the company’s mobile technicians can ensure that any insulation material is performing to the specified standards incorporated within its design. Mobile Test ‘n’ Cal are qualified to meet compliance and mandatory requirements for the complete range of electrical measuring devices and safety equipment including; Insulated Gloves; Insulated Mats; Rescue Kits; Hot Sticks; Elevated Working Platforms; Tiger Tails; RCD Testers; Insulation Testers; Multimeters; Clamp meters; PAT Testers; Multifunction Testers and Voltage Testers and much more. As for gold medals? Not quite but Mobile Test ‘n Cal does win its share of awards including a recent 2013 NECA Excellence Award for the company’s contribution to Boom Sherrin’s fleet of Elevated Working Platform trucks. The 78 strong rental fleet had to be tested for post-rebuild acceptance in a process expected to take around 12 months. Mobile Test ‘n Cal‘s first challenge was to secure the right testing machinery and this meant sourcing High Voltage testing apparatus capable of testing up to 300kV from overseas. This was achieved very quickly and as soon as each rebuild was completed Mobile Test ‘n Cal conducted the appropriate tests so that each truck would be available for rental as soon as possible. The company also rectified certain problems that were discovered following the rebuild to ensure that each EWP presented a safe and functional working environment. Executive Director of National Electrical and Communications Association (NECA) in Queensland, Mr Mick Logan, said in presenting the award to Mobile Test ‘n Cal and other winners; “The electrical and communications contracting firms that have won an award today are simply outstanding for what they have achieved during each project.” According to Mr Logan, the winning companies were chosen because of their commitment to excellence, significant engineering achievements and most importantly their ability to integrate many different technologies into the one project. In itself the award, like many others the company has received, highlights the dedication of Mobile Test ‘n Cal to maintain the highest standards of service. Perhaps it’s that consistency in delivering a gold medal performance every time is why the company will continue to win new business and attract new franchises across the country. For more information about Mobile Test ‘n Cal visit; www. hvtest.com.au or phone; 1300 662 119. Australian Power & Energy News - Page 23

Renewable energy exports drive record profit Key results: Operating profit before fair value movement and tax $238m Operating cash flow $262m Capital works on hydro asset program $58m Total group revenue Returns to government 2012/13

Above: CEO Steve Davy and Chair David Crean announcing annual results

NCREASED revenue from renewable energy exports to mainland Australia helped Hydro Tasmania record the largest profit in its history. The business recorded a profit before tax and fair value movements for 2012/13 of $238 million, more than double last year’s record result. This included around $70 million from the carbon price and a similar amount from increased generation which saw record exports across Basslink. This result will see an expected return to the Tasmanian Government during 2013/14 of $263 million, including a dividend of $116 million. During 2012/13, the business returned $125 million, including a dividend of $51 million. Chair Dr David Crean said that over the next two years Hydro Tasmania expected to return more than $450 million to the State. Dr Crean said that while the outlook after 2014 was more uncertain given the subdued wholesale electricity market, reduced customer demand and uncertainty over carbon pricing, Hydro Tasmania was nevertheless demonstrating its importance as Australia’s leading renewable energy business. “This was a year in which the true value of the State’s 100-year investment in renewable energy was finally realised,” Dr Crean said. “The performance is also notable for the increased proportion of our revenue and profit which comes from the mainland. At the same time we continue to be a major purchaser of Tasmanian goods and services with almost

$125 million spent locally during the year. “When combined with our expected returns to government in the next year making up around 13.5 per cent of the Government’s statesourced revenue, it reinforces the value of our business to the entire Tasmanian community.” Dr Crean said that while Hydro Tasmania had carefully pursued opportunities interstate and overseas to strengthen the business and maintain strong returns to shareholders, it remained committed to its primary role as the power generator to the Tasmanian community. He said the annual result also highlighted the importance of Basslink to the State, as well as the acquisition of mainland retail business Momentum Energy. “Without Basslink to export our surplus renewable energy to the rest of Australia, the State would have failed to realise many of the benefits of its long-term investment and the national carbon price,” Dr Crean said. “And it was a year that saw Momentum Energy significantly increase its revenue to around $800 million as it continued to perform strongly in the highly competitive interstate market while returning the benefits to its Tasmanian owners through an increased profit of more than $17 million. “While the year also had its challenges, these cannot take away from what has been an eventful and important 12 months as we prepare to recognise and celebrate 100 years of state-driven investment in hydropower and renewable energy in 2014.”

$1578m $125m

Expected returns to government 2013/14 $263m CEO Stephen Davy said the business success had been achieved in a challenging operating environment. Mr Davy said there had been significant focus on the Tasmanian Government’s reforms of the electricity sector, which saw the transfer of the Tamar Valley Power Station to Hydro Tasmania on 1 June 2013, as well as planned regulation of the wholesale electricity market reform. The completion of the Musselroe Wind Farm in north east Tasmania was also a key focus for the business, as was the 75 per cent sell-down of the project in early 2013. During the year, the business announced a concept for a 600 MW wind farm on King Island. TasWind, as the project is known, would involve a high-voltage underwater cable across Bass Strait to connect the wind farm to the National Electricity Market. There was a sixmonth consultation project on the island that culminated in a survey of the community which found 59 per cent of respondents supported the project proceeding to feasibility.

Mr Davy said TasWind had generated significant community debate on the island and attracted industry and media interest nationally and from overseas. The project would not proceed to the development stage without the ongoing support of the King Island community. “A key focus for the business during the year was on improving the way we communicate with our stakeholders and the Tasmanian community in particular,” he said. “The effort undertaken on King Island for the TasWind project was particularly important to ensure the community was well-informed before making any decision about moving to the next stage. “And our community engagement work around the Musselroe project was recognised nationally with an award from the Clean Energy Council of Australia. “Engaging with the communities in which we work and operate to seek their input and views on our activities is integral to the way we conduct our business.” Other highlights of the year include: * The decommissioning and rehabilitation of the Lagoon of Islands in the Upper Derwent * The success of Hydro Tasmania’s staff volunteering program that saw more than 20 per cent of Tasmanian-based staff supported by the business to spend time helping community organisations across the State * Our consulting business Entura continuing to export Tasmanian expertise to the world * Business-wide upgrade of our outdated IT systems

Above: Gordon Dam, one of Hydro Tasmania’s major storages. Storages were deliberately built up ahead of the introduction of a price on carbon, to ensure we were able to maximise returns on the carbon price

Entura opens doors in southern Africa

YDRO Tasmania and its consulting business Entura have broken ground in a new international market, with the official launch this week of a hydropower project in South Africa.

Entura has been involved for two years in the Neusberg project, which is a run-of-river small hydropower project under construction on the Orange River near Kakamas in the Northern Cape of South Africa. Construction officially began this week with a sod turning ceremony. Entura’s role encompasses the whole lifecycle of the project from design through construction and ongoing support for the operation and maintenance after completion in January 2015. Hydro Tasmania also plays a role in the Neusberg project as developer and 25 per cent equity participant in the project company Kakamas Hydro Electric Power (Pty) Ltd, together with Hydro 1 SA (Pty) Ltd, Old Mutual, and a community trust funded by the Industrial Development Corporation. “The project brings great benefits to the local community, both through ensuring a financial share in the project through the community trust, and through job creation for work on the scheme,” said Stephen Davy, Hydro Tasmania Page 24- Australian Power & Energy News

Chief Executive Officer. The Neusberg project is the first run-of-river small hydro scheme to be delivered under South Africa’s Renewable Energy Independent Power Producer’s Program and will deliver 10 MW of base load power in the South African energy market. “Southern Africa presents great opportunities for Entura as the country seeks to develop its renewable energy potential, with only seven per cent of Africa’s potential hydropower resources currently developed,” Mr Davy said. “Winning projects in this region further enhances Entura’s and Tasmania’s international profile as a clean energy leader.” Neusberg is one of several consulting projects being undertaken by Entura in southern Africa, including the identification of opportunities to install mini-hydro hydropower systems on existing water supply infrastructure in Durban, and a water optimisation study for the Ncondezi group in Mozambique. To better support Entura’s entry to the southern Africa market, it has established an office in Cape Town for its people involved in these projects and as a base for further operations in the region.

Above: Representatives from Entura and Hydro Tasmania with special guests at sod turning