Initial Plant Assessment Report

(Public Release Version)

RATCH-Australia
Collinsville Solar Thermal Power Station
www.ratchaustralia.com

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Table of Contents

Introduction ............................................................................................................................................ 3
Technical-Initial Plant Assessment Report .............................................................................................. 4
Overview ............................................................................................................................................. 4
Assessment of existing equipment and unit selection ....................................................................... 4
Refurbishment plan ............................................................................................................................ 5
New plant alternative ......................................................................................................................... 5
Comparison of alternatives ................................................................................................................. 5
Solar layouts........................................................................................................................................ 6
Refurbishment option (Solar Field Option 1) ...................................................................................... 6
New equipment alternative (Solar Field Option 2) ............................................................................. 7
Gas Supply Concept Study: ..................................................................................................................... 8
Preliminary Environment Assessment Report ........................................................................................ 8
Overview ............................................................................................................................................. 8
Scope of Work ..................................................................................................................................... 9
Summary of Findings........................................................................................................................... 9

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Introduction

RATCH-Australia Corporation Limited (RAC), in partnership Transfield Infrastructure Pty Limited, and
The University of Queensland (UQ), is undertaking all the preparatory development work to assess
the viability of converting an existing 180MW coal fired power station to a 30MW hybrid solar
thermal / gas power station at the existing Collinsville Power Station (CPS) in Queensland (the
Project).

As a part of the project, RAC will also examine the feasibility of using Novatec’s Supernova Linear
Fresnel Solar Thermal technology to generate superheated steam to be supplied to steam turbine/s
to provide grid connected electricity. The dual-fuel boiler will also be designed to use natural gas to
enhance grid reliability from the Project.

The Australian Government, through an Australian Renewable Energy Agency’s (ARENA) Emerging
Renewables Program Funding Agreement, is providing the funding for the completion of the
feasibility study.

One of the key deliverables for Milestone 2 is this Initial Plant Assessment Report for Public
Release, which contains a summary of the non-commercially sensitive information from the
following sections:

 Technical-Initial Plant Assessment Report: RAC’s technical advisors have completed an

initial assessment of the Project which includes:
 Reviewing the condition of the existing equipment and identifying the refurbishment
requirements.
 Preparing preliminary solar field design
 Compare the installation of a new steam turbine with the reuse of the existing
steam turbine.
 Gas Supply Concept Study: The aim of this study is to identify the processes involved and
alternatives available to provide commercial quantities of gas to support the Project.
 Preliminary Environment Assessment Report: RAC engaged an environmental consultant to
undertake an Environmental Opportunities and Constraints Assessment, to determine the
potential environmental constraints to the proposed development of the site.

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Technical-Initial Plant Assessment Report
RAC engaged technical advisors to provide the initial technical assessment of the Project. This report
provides a detailed assessment of the existing plant with respect to refurbishment requirements for
the proposed Project scope, culminating in:

 a detailed assessment of existing plant with respect to refurbishment requirements for the
proposed Project scope
 a technical, cost and risk comparison of:
 the installation of a new steam turbine, compared to
 the reuse of the existing steam turbine
 the preliminary solar field design; and
 Identification of any technical fatal flaws.
Overview
This initial technical assessment indicates there is the potential for repowering and life extension of
a selected unit at CPS for operation as a solar thermal power plant for the next 25 years. In addition,
there is the potential to use some of the existing equipment, supporting infrastructure and services
at the CPS for the proposed Project to reduce the overall Project costs.

The detailed refurbishment program, including the power-block, existing equipment, supporting
infrastructure and services and dual fuelled fossil fired boiler, represents a significant investment.
However, no fatal flaws with the refurbishment option were identified.

CPS’s specific historic installation, maintenance and operating regime results in a substantial portion
of the power-block requiring replacement and refurbishment. This results in only a moderate capital
cost saving when compared to the installation of a new power-block.

A new power-block provides a technically superior, more reliable and lower risk option, along with
the added benefits of increased solar generation yields and reduced fossil fuel cost due the higher
efficiency of the new plant. Another major benefit of the installation of a new power-block is the
ability to use traditional lower risk Project delivery mechanisms supported by warranties, such as a
traditional engineer procure and construct (EPC) wrap contract, and the expected associated
improved funding conditions.

Assessment of existing equipment and unit selection

An assessment of the four existing 30 MW power blocks and supporting equipment at CPS was
completed to establish which components should be retained for the Project.

This assessment evaluated the plant under three disciplines; mechanical, electrical and
instrumentation and control. The mechanical and electrical plant was assessed for its condition and
suitability for continued reliable operation with recommendations of what, if any, changes or
modifications should be made in order to ensure that it will provide continuous reliable operation
during this future operational period. As the instrumentation and control system is currently over
fourteen years it is expected that the entire control system would be replaced and as such no
detailed assessment of the existing equipment was undertaken.

This initial assessment identified Unit 4, 30 MW unit commissioned in 1971, as the preferred power
block for refurbishment for the solar power plant. This is primarily driven by the condition status of
the major mechanical plant being the steam turbo-generator.

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Refurbishment plan
The minimum refurbishment plan involves a total replacement of most equipment except for a
refurbishment of the main mechanical plant including the steam turbine generator, condenser and
low pressure side of the feed heating plant.

A summary of the proposed refurbishment plan for based on a Unit 4 rehabilitation would be as
follows:

 full mechanical refit of the steam turbine and associated systems

 re-tubing of the condenser
 refurbishment of the condensate extraction pumps and LP heaters
 replacement with new equipment for HP heaters, boiler feed pumps, de-aerator, a majority of
valves, turbine governing system and monitoring, cooling tower and water treatment system
 refurbishment of the remaining station plant systems including water, fire and air compressors
 full electrical and mechanical refit of turbine generator and associated systems
 replacement with new excitation and AVR system
 replacement with new equipment for all transformers (except for four smaller units),
switchboards, cabling, DC systems, UPS and electrical protection systems
 Replacement with new equipment for all instrumentation and control equipment including the
ICMS.
A possible extension to the base case for the steam turbine refurbishment process that would
significantly increase long term performance and reliability is a full refit or modular turbine upgrade.
However this undertaking results in a substantial increase in the rehabilitation price. For the
purposes of the comparison between refurbishment of the existing steam turbine and the
installation of a new steam turbine the base case pricing has been used.

New plant alternative

Adopting a ‘new’ power block approach located in near vicinity to the existing CPS provides
substantial benefits although will be more expensive from an initial capital expenditure perspective.

The advanced design incorporated in the steam turbine generator and integrated equipment
provides various benefits, including:

 significantly improved levels of overall cycle efficiency can be obtained by use of a two cylinder
reheat turbine with a moisture separator reheater (MSR) specifically designed and engineered
for solar applications
 fast start up capability and improved loading cycling performance which again improves the
generation yield; and
 the solar to electrical conversion efficiency is very high with limited use of the fossil fuel.

Finally all new equipment will be compliant with the latest and more onerous standards and safety
requirements thereby helping to reduce the risk to operational and maintenance personnel.

Comparison of alternatives

CPS’s specific historic installation, maintenance and operating regime results in a substantial portion
of the power-block requiring replacement and refurbishment, resulting in only a moderate cost
savings when compared to the installation of a new power-block.

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An initial estimate for the refurbishment is includes one (1) new gas-fired superheater (and
associated equipment) with a base case refit to the steam turbine. A full steam turbine upgrade
could increase the capital cost significantly.

The energy yield modelling based on the configuration for both the existing refurbished power block
and new power block has predicted the electricity production and fuel consumption figures given in
Table 1. Both these configurations include the fossil fuelled boiler and are based on same size solar
field.

The major difference between the two plants relates to the cycle efficiency and corresponding
generation yields. The substantial increase in cycle efficiency of greater than 6% which represents
nearly a 20% improvement on the refurbished plant equates to higher levels of solar generation
yield (~14.4%) and reduced fossil fuel consumption (~21.4%).

Table 1: Key plant parameters

Existing Power Block New Power Block

Steam conditions 4.24 MPa & 454°C 12 MPa & 500°C

Maximum solar cycle efficiency 32% 38.5%

Maximum fossil fuel cycle efficiency 30.4% (LHV basis) 36.6% (LHV basis)

Total mirror area 202,230 m2 202,230 m2

Full load thermal input (approx.) 93.8 MW 77.9 MW

Maximum solar output 30 MWe 33 MWe

Maximum hybrid output 30 MWe 30 MWe

Annual solar electricity production 61.62 GWh 70.49 GWh

Annual fossil fuel electricity production 70.52 GWh 66.66 GWh

Total annual electricity production 132.14 GWh 137.15 GWh

Annual Water Consumption 371 Ml 253 Ml

Solar layouts
The solar field layout can have an aperture area in the range of 200,000 m2–260,000 m2 dependent
on final optimisation and incorporates an initial preheating and evaporation stage and superheating
section. Minimising the distance between the steam turbine with its associated balance of plant (the
‘power block’) and solar field has a significant impact on the overall solar power plant cost and
operating efficiency.

Refurbishment option (Solar Field Option 1)

The preferred option in this case would be Figure 1: Solar Field Option 1, with the solar field
separated into two subfields. This option requires re-location of an existing Powerlink transmission
line and construction works over the existing ash dam, both of which may be time consuming and
cost-prohibitive. Even in this case the more remote field would require some 900 m of steam piping
which for superheated steam is significant. These piping costs have been included in the
refurbishment estimate.

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 Figure 1: Solar Field Option 1

New equipment alternative (Solar Field Option 2)

A potential location of a green field option is shown in the layout Figure 2: Solar Field Option 2Figure
2below where the solar field lies in the area between the two transmission line routes and to the
north of the existing power station. The power block would be immediately adjacent to the southern
end of the solar field. The cooling tower and evaporation pond would be located in the same area
surrounded by the existing transmission line routes and the solar field.

Some existing equipment for CPS would be retained such as the raw supply systems, liquid fuel
storage, administration buildings and major maintenance workshops. Low cost small bore piping
would connect the raw water and fuel systems to the new power block.

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 Figure 2: Solar Field Option 2

Gas Supply Concept Study:

RAC engaged with local gas suppliers to prepare a concept study, with the aim of identifying the
processes involved and alternatives available to provide commercial quantities of gas to the Project.
The concept study proposal is based on the installation of a pipeline to supply gas from nearby
tenements to the Project.

The objective of the gas facility installation is to meet the Project’s gas ramp profile while minimising
the pre investment in capital, and in particular, the sunk capital.

An engineering study is required to confirm these findings. This will be completed in the next stage
of the project developments.

Preliminary Environment Assessment Report

Overview
RAC engaged environmental advisors to undertake an Environmental Opportunities and Constraints
Assessment, to determine the potential environmental constraints to the proposed development of
the site.

The objective of the Environmental Opportunity and Constraints Assessment is to identify potential

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 environmental constraints and opportunities to the future development of the Project site for the
purposes a solar thermal power generating facility, involving a material change of use application.

No major constraints or fatal flaws were identified in this review. Some minor constraints to be
considered during the detailed design phase of the Project were identified, as outlined in the
following section.

Scope of Work
A desktop review of relevant ecological databases, mapping overlays, legislation and associated
plans and policies was undertaken to identify mapped ecosystems and significant species and
communities, as well as other ecological features that may occur on or within the vicinity of the site.

Following the desktop review, a site investigation including an assessment of flora, fauna and
general environmental values was undertaken by two ecologists on 24 and 25 of October 2012. The
sites of the proposed solar fields (i.e. Lot 35 on SP244951 and Lot 75 on CP893830) were assessed in
their entirety. However the site for the proposed transmission line re-alignment (i.e. Lot 77 on
CP903944) is currently privately owned and could not be accessed during the survey period.
Observations of this parcel of land were made from the boundary fence and adjoining Hoffmans
Road. The area of the proposed alignment within this lot was clearly visible from this location and
the observations made were considered adequate to complete the necessary preliminary
assessment of the site.

Summary of Findings
Findings of this investigation are summarised in Table 2 below. For ease of reference, a ‘traffic light’
system was used to indicate the following:

 Green – Conditions are unlikely to constrain future development for the purposes of
industrial / power generation within the Project area;
 Yellow – Conditions may present a minor constraint to future development for the
purposes of industrial / power generation within the Project area; and
 Red – Conditions are likely to present a significant constraint to future development for
the purposes of industrial / power generation within the Project area.

Issue Result Implications and recommendations

Regional Ecosystems, The site assessment determined that the heterogeneous polygon
Regrowth Vegetation in the south-eastern portion of Lot 35 on SP244951 containing an
and Essential Habitat ‘of concern’ regional ecosystem (5%), and the heterogeneous
polygon mapped over the majority of Lot on 77 CP903944
containing an ‘endangered’ regional ecosystem (10%) were
incorrectly mapped. RAC is currently in the process of amending
the vegetation mapping via the Property Map of Assessable
Vegetation instrument to reflect its true status, ‘not of concern’.
If the remnant vegetation is assessed at its current status (‘of
concern’ and ‘endangered’), the clearing of any vegetation will
require an offset in accordance with the Policy for Vegetation
Management Offsets – Version 3 (DERM 2011);

Even where the remnant vegetation is confirmed as ‘not of

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 concern’ regional ecosystem, general vegetation management
criteria apply for the assessment of the development. Policy and
code requirements for maintaining minimum areas of vegetation
are being incorporated into the development of layout designs
for the project.

Significant Flora No significant flora species are likely to occur within the Project
area. As such significant flora species would not pose a constraint
to the development of the site.

Threatened Ecological From this assessment it was considered unlikely (low chance) that
Communities any threatened ecological communities would be significantly
impacted by the Project. Whilst lot 77 CP903944 could not be
accessed during the recent site assessment and may contain
areas of Brigalow, these areas occur outside the proposed impact
areas.

Significant Weed Two Class 2 weeds were recorded on the site - Parthenium
Species hysterophorus and Zizyphus mauritiana. One Class 3 weed was
also recorded – Lantana camara;

Landowners must take reasonable steps to keep land free of Class

2 pests; and

Landholders are not required to control Class 3 plants unless their

land is adjacent to an environmentally significant area.

Targeted weed eradication programs are being undertaken on

site by the existing Collinsville Power Station operations team.
Future weed control programs will be considered in the proposed
environmental management plan for the solar thermal project.

Significant Fauna From the assessment it is considered that one species listed
within schedules of the NCWR and the EPBC Act has a moderate
likelihood of occurrence at times within the Project area, six
species have a low to moderate likelihood of occurrence, and
eight species have a low likelihood of occurring within the Project
area;

Additionally, one species listed as migratory under the EPBC Act

has a moderate likelihood of occurrence at times within the
Project area, eight species have a low to moderate likelihood,
while three species have a low likelihood of occurring at some
time within the Project area; and

The assessment concludes that development within the Project

area is unlikely to result in a significant impact on any significant
fauna species. As such a permit under the NCA is not likely to be
required, nor is a referral under the EPBC Act in relation to listed
fauna species.

Introduced Fauna Evidence of the presence of European rabbits (i.e. scats) was

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 Species observed at a number of locations within the Project site. A
number of additional species are considered likely to occur: Pig
(Sus scrofa); Red fox (Vulpes vulpes); Cane toad (Rhinella marina);
and Cat (Felis catus).

Control of all Class 2 Pests, with the exception of the Dingo (Canis
lupus dingo) should be undertaken where effective control is
feasible and effective. Control of feral cats should be a priority.
Although Dingos are also classified as Class 2 Pest under the LPA,
and as such all land owners are required to control them (due no
doubt to their predation of stock), recent research suggests that
the presence of dingos may actually have a beneficial effect on
native mammal populations by excluding or reducing the
populations of smaller feral Cats and Red foxes (Johnson & Van
DerWal 2009).

Future control programs of Class 2 Pests will be considered in the

proposed environmental management plan for the solar thermal
project.

Aquatic Ecosystems, The Water Act 2000 (Water Act) regulates the
Wetlands and destruction/disturbance of freshwater riverine vegetation in the
Watercourses bed and banks of DNRM watercourses. In accordance with the
Water Act, watercourses are determined as watercourses by the
DNRM through topographical mapping, aerial imagery and a
possible onsite assessment.

Liaison with DNRM is required to determine if the watercourses

present on site are watercourses in accordance with the Water
Act. Pre-lodgement meetings are currently being organised with
the DEHP with regard to this aspect of the proposal.

Other Ecologically In the context of the proposed development, the Queensland

Significant Issues Biodiversity Offset Policy (QBOP) applies to the Sustainable
Planning Act 2009 for activities under chapter 4 with an aggregate
environmental score assessed under the Environmental
Protection Act 1994. As the Project requires an ERA, liaison with
DEHP is required to determine if the State Significant Biodiversity
Value connectivity is present on site and the subsequent
requirement of a biodiversity offset pursuant to the QBOP

Pre-lodgement meetings are currently being organised with

regard to this aspect of the proposal.

Good Quality As Land Suitability mapping classifies the site as ‘non arable’,
Agricultural Land which is suitable for grazing of native pastures and catchment
protection due to the inherent soil types’ unattractive agricultural
properties, it is considered that the proposed development will
not result in the loss of good quality agricultural land for cropping
purposes.

Strategic Cropping Land A review of the Strategic Cropping Land Trigger Map for the

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 Coastal Queensland Zone and Western Cropping Zone
determined that the proposed Project is not located within a
Strategic Cropping Protection Area or a Strategic Cropping
Management Area. As such, this draft SPP is not relevant to the
Project.

Land Contamination Lot 35 on SP244951 and Lot 75 on CP893830 have been included
on the EMR.

Amendments to the Sustainable Planning Regulation 2009 which

took effect on 15th March 2013 included changes to the
assessment and referral triggers for contaminated land. Under
these amendments the site is not a ‘potentially affected
premises’, and thus referral for contaminated land matters is not
required for this application.

Bushfire Hazard As the Project area encompasses mapped medium bushfire

hazard area, any future development of the Project area that
requires a material change of use or reconfiguration of lot
application will be assessed against the Bushfire Management
Overlay Code. Liaison with Whitsunday Shire Council is required
to confirm if the proposed development is required to be assess
against the Bushfire Management Overlay Code; and

If there is a requirement for the development to be assessed

against the code, development design that considers the overlay
code will be required. As such, it is recommended that following
the finalisation of the development layout and the identification
of the extent of vegetation to be removed, a detailed bushfire
hazard assessment is undertaken to assess the bushfire hazard
risk of the development and allow for adequate mitigation
features.

Table 2: Summary of Findings

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