At Century Yuasa – Power Systems, we excel in delivering reliable, customised DC power solutions tailored to the unique demands of the rail industry, which has made us a trusted partner for rail projects across Australia. Our commitment to innovation and quality was recently demonstrated when we were chosen to support the development of a new narrow gauge rail line in Central Queensland.
This 200 km rail line, extending from a new mining site, required a robust and dependable power system to ensure seamless signalling and control operations in one of Australia’s most challenging environments. This case study explores how Century Yuasa delivered the Intelepower DC systems successfully to meet the project’s complex requirements while maintaining the highest standards of quality, safety, and reliability.
Project Overview
To meet the complex power requirements of this vital rail line, Century Yuasa undertook the task of designing, constructing, and managing multiple solar power systems, each equipped with advanced battery arrays. The project was set in Central Queensland—a region characterised by extreme temperatures, high humidity, frequent lightning, cyclonic weather, and constant rail traffic. These challenging environmental conditions demanded a resilient and reliable power solution. Our team adopted a stringent design approach focused on resilience and long-term performance, ensuring that the systems would perform optimally under all conditions.
Our Intelepower solar installations were equipped with battery backups and the option for a temporary standby generator supply via a changeover switch, allowing continuous battery recharging. This setup was crucial to maintaining an uninterrupted power supply during extreme weather events and in remote locations where access to conventional power sources might be limited. We prioritised energy efficiency to minimise power consumption and reduce heat build-up within control cabinets. Our cabinet designs featured natural ventilation to keep internal temperatures within safe limits, ensuring optimal equipment functionality and longevity.
Optimising Power Efficiency and Longevity through Careful Design
Century Yuasa’s approach to this project was underpinned by meticulous planning and technical precision. Each aspect of the design was carefully considered to ensure maximum efficiency and durability. We conducted comprehensive power consumption and battery reserve calculations for each site, allowing only a 50% discharge to optimise battery life. This approach helps prevent deep discharges that can shorten battery lifespan, thereby reducing maintenance costs and improving overall system reliability.
The solar systems and batteries were designed to provide a minimum service life of 10 years, with a maximum allowable output degradation of 10%. This long-term approach ensures that the systems remain effective and efficient throughout their operational life. Additionally, the battery banks and solar arrays were engineered to sustain operations for at least four days without sunlight, providing reliability even during prolonged adverse weather conditions. This design consideration is crucial in Central Queensland, where weather patterns can be unpredictable and harsh.
For this project, we deployed Century GB OPzV lead-acid batteries, available in capacities ranging from 187 to 539Ah. These batteries are specifically designed for cyclic solar applications in extreme environments, making them ideal for the demanding conditions found along the rail line. Their robust construction and advanced technology provide excellent reliability, even in the face of Central Queensland’s challenging environmental conditions.
Each solar and battery site was integrated with network connectivity, enabling remote monitoring and diagnostics. This functionality allows for quick detection and resolution of any issues, minimising downtime and maintaining consistent power delivery. By providing the capability for remote access, we ensure that maintenance teams can respond quickly to any issues, reducing the need for on-site interventions and enhancing overall operational efficiency.
Targeted Project Planning to Maximise Efficiency
The scope of work for this project was extensive and comprehensive, reflecting our commitment to quality and customer satisfaction. Intelepower’s role included:
- Supply and Installation: We provided all necessary Intelepower components, including solar arrays, mounting frames, solar charge regulators, Century GB OPzV batteries, battery racks, and essential spares. Our team ensured that each component was installed to the highest standards, ensuring long-term reliability and performance.
- Remote Monitoring and Communication: We integrated remote communication interface equipment for real-time monitoring and proactive management. This allows our clients to monitor system performance remotely and respond quickly to any issues, ensuring uninterrupted power supply.
- Training and Documentation: Our team delivered extensive training on operations and first-line maintenance, supported by detailed manuals and as-built documentation. This training ensures that the client’s staff are fully equipped to manage and maintain the systems, enhancing long-term reliability and reducing maintenance costs.
- Project Management: Century Yuasa coordinated closely with the Engineering, Procurement, and Construction (EPC) contractor and the end client. We actively participated in design meetings, project progress updates, and site coordination activities to ensure seamless project delivery. Our project management approach focuses on collaboration and communication, ensuring that all stakeholders are aligned and working towards common goals.
- Logistics and Supply Chain: We managed the efficient shipment of all equipment to the client’s Brisbane warehouse, ensuring timely and cost-effective delivery. Our logistics team worked closely with suppliers and transport companies to ensure that all components arrived on time and in excellent condition.
Outcomes and Value Delivered
The successful execution of this project demonstrates our ability to provide innovative, high-quality power solutions that meet the rigorous demands of the rail industry. By leveraging our deep expertise in DC power systems, we delivered a robust and reliable energy solution that ensures uninterrupted operations, even in the most challenging environments.
Our commitment to using locally manufactured, high-quality components, combined with a dedicated nationwide service team, ensures that our clients benefit from maximum reliability and performance. This project not only strengthened our reputation as a reliable partner in the rail sector but also showcased our capability to provide tailored solutions that enhance operational efficiency and safety.
Closing Insights and Future Outlook
We are dedicated to powering the future of rail with innovative, dependable DC power solutions. Our recent project in Central Queensland showcases our expertise in delivering customised solar power systems with advanced battery backups, designed to withstand the harshest conditions and maintain critical rail infrastructure operations.
By choosing an Intelepower DC System made by Century Yuasa, you are partnering with a company that values quality, reliability, and customer satisfaction. We are committed to delivering solutions that meet your specific needs and exceed your expectations.
For reliable, high-performance power solutions tailored to your rail needs, contact Century Yuasa today and discover how we can help you achieve seamless and efficient operations.