Bald Hills Wind Farm

The Bald Hills Wind Farm is located approximately 10km south east of Tarwin Lower in South Gippsland, Victoria on a site of approximately 1750ha of largely cleared cattle and sheep grazing farm land.

The project comprised the design, supply and installation of the substation and 33kV reticulation for 52 SENVION MM92 wind turbines.

​The Bald Hills Wind Farm construction included the procurement and installation of:

  • 2 x 70MVA 66/33kV power transformers
  • 66kV Switchgear
  • 52 x SUT Kiosks
  • MV & LV cables
  • transportable control/switch room
  • 33kV indoor switchboard
  • protection and control equipment
  • operations and maintenance buildings

Wind Farm Reticulation

The wind farm electrical reticulation network consists of approximately 46,000 metres of direct buried 3 core aluminium XLPE cable connecting the wind turbines to the wind farm substation.

Wind Farm Substation

The wind farm substation comprises two (2) 70MVA, 66/33kV transformer bays and associated 66kV switchgear, two (2) indoor 33kV switchboards housed in a transportable building which also includes a SCADA room and AC/DC room and two (2) 33kV reactive plant bays and associated 33kV switchgear.

The electricity generated by the wind farm is transmitted via a double circuit 66kV sub transmission line from the wind farm substation at the northern end of the site to AusNet’s Leongatha South switchyard.

Crookwell 2

CPP was appointed by TransGrid to construct the Crookwell 2 WF Grid Connection including the 330kV Transmission Line Cut-in.

The Crookwell 2 WF construction involved:

  • Supply delivery and construction of earthworks, Drainage, Access Roads, Minor and Major foundations including spill oil tank and transformer bund.
  • Installation of all primary, Secondary and communication systems including earthing, structures, equipment, cabling, Cable terminations and Microwave scope of work.
  • Design, Procure and construct Secondary system building.
  • Secondary System factory acceptance testing.
  • Secondary equipment site acceptance testing
  • Primary and Secondary Testing and Commissioning including assisting the client during energization
  • Fabrication, supply, assembly, erection, installation and cut-in of the one new 330kV new double circuit steel lattice RTE structure, stringing of Mango conductors and 2×7/3.75mm SC/AC OHEW including associated fittings and insulators.
  • Supply and Construction of tower footing and associated works. Test assembly of tower. Replacement of 3km of existing OHEW

Hornsdale Wind Farm Stages 1, 2 and 3

PROJECT SUMMARY

The Hornsdale Wind Farm is located at Hornsdale, approximately 30km north of Jamestown in South Australia. When completed, it will consist of 99 wind turbines with a generation capacity of 315 megawatts.

Our scope of works across all three stages was to design, construct and commission the substations and connection to the grid including reactive plant support.

Stage 1
involved the construction of 32 Siemens 3.2MW turbines, 55km of HV cable between turbines. One substation which included a 120MVA transformer, auxiliary transformer, control room, two reactive bays and a 275kV protection and switching bay.Stage 2
involved the construction of 32 Siemens 3.2MW turbines, 50km of HV cable between turbines. One substation which included a 120MVA transformer, auxiliary transformer, control room, two reactive plant bays and a 275kV protection and switching bay.

Stage 3
involved the construction of 35 Siemens 3.2MW turbines, 55km of HV cable between turbines. One substation which included a 150MVA transformer, auxiliary transformer, control room, two reactive plant bays and a 275kV protection and switching bay. A total of 99 Siemens turbines providing a total output of around 315MW.

Kiata Wind Farm

PROJECT SUMMARY

The Kiata Wind Farm project is a 29.7 MW wind farm consisting of 9 Vestas V126 3.45MW wind turbine generators (WTGs) connected into the National Electricity Market (NEM). The Wind Farm is located in western Victoria, Australia, near the town of Nhill.

We were appointed as the Balance of Plant (Civil and Electrical) contractor for this project.

The Kiata Wind Farm project included the procurement and installation of:

  • 2 x 22MVA 66/33kV power transformers
  • 66kV switchgear
  • MV cables
  • Transportable control room
  • 33kV outdoor switchgear
  • Protection and control equipment
  • Operations and maintenance building

The civil balance of plant included the design and construction of approximately 6000 metres of access tracks, 9 WTG hardstands and 9 WTG foundations. An onsite concrete batching plant was also established to supply the almost 4500m³ of concrete required for the project.

The wind farm electrical reticulation network consists of approximately 6,000 metres of direct buried 3 core aluminum XLPE cable connecting the wind turbines to the wind farm substation.

The wind farm substation comprises two (2) 22MVA, 66/33kV transformer bays and associated 66kV switchgear, two (2) outdoor 33kV feeder bays. A transportable building which houses al of the required protection and control equipment together with a separate operations and maintenance building.

Musselroe Wind Farm

The Musselroe Wind Farm is located at Cape Portland Bay, 30km north east of Gladstone, Tasmania.  Musselroe wind farm was a particularly challenging project due to the cultural heritage and environmental significance of the area.

We were appointed as the Electrical Balance of Plant contractor for this project.

The Musselroe Wind Farm construction involved:

  • The design, supply and construct the 110/33kV Musselroe substation and 33kV reticulation for 56 Vestas V90 wind turbines
  • Procurement and construction of 46kms of 110kV transmission line from Derby to the Musselroe Wind Farm which included 158 poles
  • Access tracks and hardstands for the 110kV overhead line works  and foundations
  • Turbine earthing and MV circuit cabling installation and terminations
  • The procurement and installation of:
    • Two 110/33kV 90MVA power transformers
    • Two 33kV 14MVAr synchronous condenser units with two 33/13.8kV transformers
    • Four 4MVAr D-Var Statcoms with 33kV/480v Transformers
    • Four 33kV 10MVAr Filter Bank systems
    • All 110kV & 33kV equipment including the WTG 33kV ring main units
    • 55kms of MV cable from the substation to the 56 WTG’s

Snowtown Wind Farm – Stage II

PROJECT SUMMARY

The 250MW Snowtown Wind Farm Stage II development was constructed on the Barunga Ranges near Snowtown in rural South Australia and comprises 90, 3MW wind turbine generators.

We were appointed as the Electrical Balance of Plant contractor for this project which comprised the design, supply, installation and commissioning of the wind farm 33kV underground reticulation, wind farm 275/33kV substation and 33kV internal overhead line.

Wind Farm Reticulation
We designed, supplied, installed and commissioned 120,000 metres of 33kV direct buried MV cable including fibre optic and earth to link the 90 turbines to the substation site.Wind Farm Substation
We designed, suppled, constructed and commissioned the 275/33kV wind farm substation, including 2 x 275/33kV 160MVA power transformers, control building with indoor switchgear, reactive power plant, protection and control and other associated substation electrical plant/equipment.

Overhead Lines
We designed, supplied, constructed and commissioned 14.5km’s of dual circuit and 5km’s of single circuit 33kV overhead line support by steel monopoles including an access track along the length of the OHL and crane pads at each pole location. We used a helicopter to string the overhead line conductor to accelerate the program.

Hornsdale Wind Farm Battery Energy Storage System

PROJECT SUMMARY

The 100MW Hornsdale Battery Energy Storage System will be the world’s largest lithium ion battery installation.

Installed adjacent to the Hornsdale Wind Farm in the mid-north of South Australia, the battery system will charge using renewable energy from the Hornsdale Wind Farm and then deliver electricity during peak hours to help maintain the reliable operation of South Australia’s electrical infrastructure.

We designed and constructed the battery energy storage yard and the 275/33kV substation.

The Hornsdale Wind Farm BESS project included:

  • The construction of the battery energy storage yard, including earthworks and foundations
  • Installation of Tesla battery power packs and inverters
  • Installation and commissioning of 33 x 33kV step up transformers
  • Supply and installation of 33kV MV cables linking the battery energy storage system to the new 275/33kV substation located within 400m
  • Construction and commissioning of the new 275/33kV substation

Wandoan South Battery Energy Storage System 132/33kV Substation Energisation

The objectives of the project included:
  1. Provide a BESS capable of generating a net 100 MW output at a power factor of 0.93, in accordance with the National Electricity Rules (NER) and approved Generator Performance Standards (GPS), into the 132 kV network at the Connection Point to Powerlink’s Wandoan South Substation;
  2. Provide energy storage discharge capacity of 150 MWh at the Connection Point;
  3. Participate in the wholesale energy market;
  4. Provide frequency control ancillary services (FCAS);
  5. Provide reactive power and voltage control at the 132 kV Connection Point bus.

The Project includes battery systems, power conversion systems, step-up transformer(s), 132 kV Substation, control systems and all other electrical, civil, mechanical and auxiliary plant works necessary for a fully functioning BESS installation. The Project is connected to the Powerlink network via a 132kV underground transmission cable provided by Powerlink.

CPP was engaged by Doosan GridTech Inc and was responsible for the successful design, construction and commissioning of the following;

132/33kV Substation design and construction

132 kV Equipment:

  • Surge arresters
  • Voltage transformers
  • Current transformers
  • Earth switch
  • Circuit breaker
  • 132 kV underground line terminating structure
  • Protection cabinet for 132 kV Circuit Breaker
  • Circuit Breaker Control Panel for 132kV Yard including RTU for monitoring/control

33kV Transformer side surge arrestors

33kV switchroom building:

  • 1 x incomer panel 2500A
  • 5 X feeder panel 1250A
  • 1 x VT
  • 1 x busbar earth switch
  • 12 x protection relays
  • SCADA System and associated testing and commissioning
  • UPS and DC system (if required) to be 10 hour rated
  • Fire Suppression System in BESS

Electrical earthing for substation, bonding of BESS earth grid and coordination of earthing to Wandoan South Powerlink Substation

NER (Neutral Earthing Resistor)

Installation of Power Quality Meters, 1 x at 132kV level, 1 x at 33kV incomer level and 3 x 33kV outgoing circuits

33kV cabling (PCC Transformer to 33kV Switchboard; supply, install and termination of 33kV cable onto switchboard by others)

All trenching needed for the substation power, control and communication cables

Free issued equipment:

  • Main Power Transformer
  • Plant Control Panels x 2

Auburn Substation

This project included the construction of a traction substation for Railcorp at Auburn, Sydney. The project was delivered on time to the standards of Railcorp.

The activities included a concrete piled and shotcrete retaining wall adjacent to the live railway tracks. The substantial site works, included excavation, deep footings, a myriad of ducts and cabling including undertrack crossings and connections to transmission line structures.

The building structure was substantial and was constructed within a very tight construction space. The site was challenging with several complexities. The substation was within the rail corridor necessitating full-time monitoring and daily safety briefings regarding hazards associated with this environment.

The site was adjacent to Rawson Street with significant traffic flows requiring ongoing traffic management for site access. The site was within a floodway that required substantial deviation arrangements for site protection.

The site had live 33kV transmission lines overhead which required innovative methods for completing construction works such as roof truss installations and heavy machinery access.

Key Challenges:
  • Traffic management
  • Demolition of the existing substation
  • Substantial flood water deviation work