Rockdale Zone Substation Equipping

Rockdale Zone Substation Equipping
Quick Facts
ClientAusgrid
LocationSydney, NSW
Value$2.2M
TimingOctober 2016 - July 2017
ContractConstruct only
SectorRegulated

Zinfra was contracted for the electrical equipping of the Rockdale Zone Substation in the suburbs of Sydney.

Quick Facts
ClientAusgrid
LocationSydney, NSW
Value$2.2M
TimingOctober 2016 - July 2017
ContractConstruct only
SectorRegulated

As the Principal Contractor, Zinfra managed its employees and contractors, as well as Ausgrid Separate Contractors who included ABB, Wilson Transformers and Century Yuasa. The client free-issued most equipment and provided the design.

The scope of works for Zinfra included:

  • Installation of electrical equipment such as Siemens 11kV switchgear panels

  • Installation of two complete AFLC rooms

  • Installation of earthing and auxiliary transformers

  • Equipping and installation of all protection, control and SCADA panels

  • Supply and installation of all steel structures, 132/11kV cable support structures and cable ladders

  • Supply and installation of all power, protection, fibre and control cables

  • Installation of all 132kV cables (2,000sqmm, 1,600sqmm and 400sqmm cables)

  • Installation of all 11kV cables

  • High voltage testing of all electrical equipment

  • 132kV and 11kV cable jointing and terminations

  • SCADA and IEC61850 testing

  • Transport to site, unloading and cranage of electrical equipment

  • Testing and commissioning of the whole system

Challenges

The small site meant careful planning and adherence to a strong Safety First culture was critical. There were many contractors and resources working in a small footprint substation at the one time.

This project represented Zinfra’s first substation construction project with Ausgrid, therefore careful attention was required to ensure compliance to the client’s standards.

Strong stakeholder management skills and a collaborative approach were required to manage the multiple parties involved: Zinfra’s employees, contractors, Ausgrid’s Separate Contractors, and the client.

Testing and commissioning was a complex process due to the need to comply with Ausgrid’s systems and standards as well as to incorporate testing of the IEC61850 design protocol which was implemented in various aspects of the project.

Despite the challenging testing and commissioning environment, Zinfra finished all testing and commissioning satisfactorily.

Achievements

The installation of 36 x 11kV Siemens switchgear panels was completed on time. Every panel was delivered to site in two heavy crates of almost 1,000 kilograms each. Our site personnel set up a small crane structure to safely install them in position. Zinfra also installed all cabling between the panels as per Ausgrid’s design drawings and schematics.

The installation of 36 x 11kV Siemens switchgear panels was completed on time. Every panel was delivered to site in two heavy crates of almost 1,000 kilograms each. Our site personnel set up a small crane structure to safely install them in position. Zinfra also installed all cabling between the panels as per Ausgrid’s design drawings and schematics.

Ausgrid was kept well informed of any issues throughout the program, with systematic, timely and professional communication handled through the RFI system put in place by Zinfra.

The completed substation was finished to a high standard, one that Zinfra is proud of.

There were no major defects in the final list from the client which strongly reflects the high standard of workmanship delivered by Zinfra on this equipping project.

Safety

As Principal Contractor, Zinfra managed site safety with an excellent record, especially as works were over the Christmas period.

Approximately 20,000 hours were worked on site with no recorded Lost Time Injuries, First Aid/Medical Treatments, Safety or Environmental Incidents.

Two Ausgrid safety audits during the project returned minimal recommendations.