Powering Shell Energy’s Neerabup Outage Facility

Powering Shell Energy’s Neerabup Outage Facility

Shell Energy, the retail division of global energy leader Royal Dutch Shell, serves millions of customers across Australia, delivering tailored energy solutions for residential and commercial needs. When the time came to refurbish critical infrastructure at their Neerabup Power Station in Perth, Western Australia, the challenge was clear: maintain operational integrity of a live site while enabling major turbine maintenance. Cablewise worked closely with Shell Energy, Siemens, and engineering consultants Stantec to execute a highly specialised solution on time, on budget, and with zero disruption to ongoing operations.

Challenges Faced by Shell Energy

The Neerabup Power Station, a vital asset in Western Australia’s energy grid, houses two gas turbine units that had reached a phase in their lifecycle requiring comprehensive servicing and refurbishment. This necessary maintenance posed a multifaceted challenge:

• Live Site Constraints: The power station needed to remain operational throughout construction, necessitating strict adherence to safety protocols and non-disruptive execution.
• Bespoke Infrastructure Requirements: Siemens, the turbine OEM, required a specially designed outage facility to support the refurbishment process, one not previously in place at the site.
• Complex Electrical Demands: Establishing a temporary facility with high-voltage capabilities, compliant earthing systems, and reliable power distribution was technically demanding and risk-sensitive.
• Multi-Stakeholder Coordination: Effective collaboration between Shell, Siemens, Cablewise, Stantec, and various subcontractors was essential to keep the project aligned and moving forward.

In essence, Shell Energy faced the task of executing a high-risk, high-precision operation within the confines of a fully functioning power station where safety, continuity, and quality could not be compromised.

Objectives

To ensure the success of this critical maintenance project, Shell Energy outlined several key objectives:

• Design and Construct a Fit-for-Purpose Outage Facility: Tailored to the technical and spatial demands of Siemens’ turbine servicing procedures.

• Ensure Operational Continuity: Avoid any unplanned disruptions to the power station’s generation capabilities during the entire project.
• Deliver Within a Tight Schedule and Budget: Maintain control over time and cost parameters without compromising quality or safety.

• Achieve Full Compliance and Safety Standards: Adhere to all regulatory requirements and high-voltage (HV) site conditions through expert consultation and review.

Solutions Implemented

By bringing Cablewise on board during the early design phase, the project leveraged the combined expertise of multiple specialists from day one. Cablewise, working in tandem with Stantec’s Electrical Consultancy team, took a comprehensive approach. By bringing Cablewise on board during the early design phase, the project leveraged the combined expertise of multiple specialists from day one. Cablewise, working in tandem with Stantec’s Electrical Consultancy team, took a comprehensive approach, starting with early audits and site investigations to foresee challenges and tailor solutions. Stantec then developed custom electrical layouts, ensuring the outage facility’s integration into the existing infrastructure met both performance and safety benchmarks. To manage every phase of implementation, Cablewise deployed an agile project management team, including a Project Manager, Site Manager, Site Supervisor, and multiple electricians.

The facility itself was a sophisticated electrical solution, featuring underground containment and power supply routed from the existing Station Main Switchboard (SMSB) to a new “Outage Facility Switchboard” inside the high-voltage exclusion zone. This main switchboard then supplied a power distribution network of multiple sub-boards, each protected by Sensitive Earth Fault Relays and built outside the exclusion zone using a TT earthing arrangement for optimal safety and compliance. The installation provided general and specialised power solutions, from high-spec lighting (including carpark zones) to power for Siemens’ specialised equipment, supporting all necessary operational requirements. Cablewise also engaged with expert subcontractors, coordinating drilling, excavation, and civil contractors, and bringing in a specialist earthing consultant to validate the installation under HV regulations. The project was completed within three months, made possible by seamless communication and coordination between all stakeholders at every milestone.

Outcomes Achieved

Cablewise successfully met the expectations of Shell Energy and Siemens, and the project was considered a strong success by the end user and consultancy team. The newly constructed facility supported the first turbine refurbishment with no performance issues, providing Siemens with the environment and infrastructure needed for precision work. Critically, the power station remained live and fully operational throughout construction, demonstrating meticulous planning and adherence to safety protocols. The project was delivered on-time and on-budget, completed within the allocated three-month schedule and under the $1M budget, underscoring Cablewise’s efficiency and cost-control acumen. Both Shell Energy and Siemens expressed client satisfaction, recognising the project as a strong success and validating the collaborative approach and technical execution. Furthermore, the works were completed safely with zero recorded incidents, meeting Shell’s high standards for health and safety, and with expert consultancy and robust design, all electrical and earthing systems achieved full HV compliance with regulatory standards for high-voltage operations.