PROJECT SUMMARY
The Tom Price client embarked on a project to replace end-of-life LV switchgear by installing a new prefabricated switch room and retrofitting the existing switch room with new MCC / PLC and auxiliary equipment to current standards. Throughout several planned maintenance shutdowns, the old equipment was removed and new equipment installed and commissioned.

SERVICES PROVIDED
The primary objectives were to replace end-of-life equipment that could no longer be maintained, with new equipment meeting current standards. This also included enhanced safety through arc flash detection systems and remote switching equipment.

The scope included:

• Replacement of end-of-life switch room with new prefabricated switch room.
• Civil/concrete/structural works to support installation of a replacement switch room.
• Replacement of existing MCC/PLC/UPS and auxiliary equipment within existing switch room building.
• Earthing systems, fire detection and suppression, HVAC, ablative cable coating and auxiliary systems.
• Work completed within and around operational plant only using planned maintenance shutdowns for disruptive work, maintaining normal plant operations.

CHALLENGES 

• During civil works, unknown redundant services were discovered. Design was modified for footings to avoid services and maintain schedule.
• Working within an operational plant and only isolating equipment during planned maintenance shutdowns required meticulous planning, coordination and execution.
• Supply issues caused late delivery of main equipment. Adjusting schedule and sequence of activities allowed schedule to remain on track.

SOLUTIONS

• Time was lost during a shutdown due to no Operations staff, on nightshift. Since then, nightshift attendance has been confirmed in advance or rescheduled to dayshift.
• SWP’s were developed for some common tasks to increase efficiency and make routine tasks safer.
• A missing ITR led to a re-test and near miss. Tasman Power is now developing an electronic completions system in response.
• Time was lost due to missing test limits. ITRs are now pre-filled by Engineering to prevent delays.