Grinding at Callide

Callide 2022 overhaul program

CS Energy is carrying out a $34 million overhaul program on two generating units at Callide Power Station from 26 March to late June 2022. We are delivering the Callide overhaul program with our Asset Management Alliance Partner Downer Group, and major contractors Intertek and Solaft.

The overhaul program will have a peak workforce of approximately 270 people, which will include approximately 220 contractors and about 50 employees from Callide Power Station’s regular workforce.

FACES OF THE OVERHAUL

Meet some of the people who will help deliver this important program of works.

Jody Scott 

Jody Scott
Project Planning and Governance Supervisor

Overhauls are a major logistical exercise, which involve getting necessary equipment to site, and working closely with contractors and suppliers to ensure everything happens to schedule. Effective planning and scheduling is essential, along with having the right governance in place for major decisions around the overhaul’s budget, duration and scope.

Jody Scott has been doing planning, scheduling and governance for the overhaul team at Callide Power Station for more than 11 years. Below she provides an insight into her role and why she loves working on overhauls.

What does your role in the Callide overhaul team entail?

As the Project Planning and Governance advisor I am involved from the early stages of planning and preparation through to the close out phase after the overhaul has been executed.

Typically, planning an overhaul follows a specific project management framework. I work to ensure we are on track in each of our planning phases and have the right timelines for detailed planning and execution. I rely heavily on software such as SAP and our scheduling tool Primavera, which enables me to produce various reports throughout execution.

What’s the most rewarding thing about working on overhauls?

Overhaul fever! I love the build up to unit ‘desync’ (taking the unit offline for overhaul) the teams coming together, contractor work crews arriving on site and watching as everyone comes together to work as one team as we have done for many years. It’s the culmination of the planning we have been doing for the better part of 16 months.

No overhaul comes without challenges, but when you’re working with the right team where everyone is focussed on the one goal, everything eventually falls into place.

How do you achieve work-life balance during an overhaul?

My husband and I both work in the overhaul team so work-life balance can be challenging at times with our children. However, I am incredibly lucky that I have the capacity to work from home if required and this flexibility allows me to juggle both daycare and school along with the longer shifts required during overhaul execution.

What is next for you after the Callide 2022 overhaul program?

Callide has multiple generating units, so when we are not executing an overhaul we are usually planning the next one. We also regularly review our processes and lessons learned, while looking at ways of improving what we do from one overhaul to the next.

Like any power station, Callide also has unplanned outages from time-to-time and I provide assistance around planning and reporting for these works.

 

Rod Callow 

Rod Callow
Outage Coordinator

Rod Callow has worked at CS Energy’s Callide Power Station for 22 years. In that time he has worked in overhauls, operations and maintenance at the power station. He was also the site supervisor of the neighbouring Callide Oxyfuel Project.

In his current role he coordinates Callide’s annual program of overhauls.

What units are being overhauled at Callide in 2022?

This year we’re overhauling Unit C3 from 26 March to 29 April followed by Unit B2 from 6 May to 17 June. There is one a week gap between the two overhauls for people to have a break, but essentially the same workforce will carry out the two overhauls.

How far ahead do you prepare for a typical overhaul?

Generally 18 months. This is because there are long lead times for certain power generation equipment and parts. We also need to plan well in advance to line up our key overhaul contractors. For example, pressure welders are in high demand and the good ones are committed well in advance.

Overhaul works
Image: Rod (far right) says he likes the logistical challenge of delivering an overhaul.

Describe a typical day for you working on the overhaul.

In the lead up to the overhaul I ensure that our budget and documentation are ready for the overhaul. During this phase I also spend a lot of time liaising with our key stakeholders, including major contractors and our warehouse, maintenance and operations personnel.

Once the overhaul starts, we’re in the execution phase and most of us work 12-hour shifts, six days a week. My focus is ensuring the overhaul is delivered safely, to a high standard, on budget and according to schedule. With COVID-19 we also implement additional hygiene controls to keep our people and the local community safety.

How do you achieve work-life balance during an overhaul?

For me it’s about staying connected with my family and friends. I like to drive to the coast to take my son reef fishing on the weekend, go out to dinner with friends, or just go for a drive near Biloela.

What’s the best thing about working on overhauls?

The reward of completing the overhaul and seeing the unit is back online and sending electricity to the grid.

the role of overhauls

As a major electricity provider, it’s critical that CS Energy continues to invest in our power stations to support the reliable supply of electricity to homes and businesses. We do this by carrying out regular overhauls and maintenance of our coal-fired generating units, which play an important role in supporting security of supply, particularly during peak demand periods.

At the same time, we are creating a more flexible and diversified energy portfolio for our owners the people of Queensland by investing in renewable energy, hydrogen, batteries, and electric vehicle charging.

covid-19 controls

CS Energy has comprehensive COVID-19 controls to keep our workers and local communities safe, support our customers and ensure a reliable supply of electricity. This includes mask-wearing, physical distancing, hygiene controls, and restricted access to certain areas of site for non-essential personnel.

To manage the extra workers on site for the overhauls, we are implementing additional COVID-Safe measures. These include:

  • Screening of overhaul contractors through rapid antigen testing and completion of a Health Check Declaration prior to their arrival at site for the first time.
  • Random RAT testing throughout the overhauls.
  • Limiting the number of people in workspaces, crib huts and buses to and from site
  • Increased cleaning and staggered meal breaks
  • Extra hygiene stations around site, and
  • Controls around lifts.