Case Studies
The Sydney Opera House
Australia’s most iconic building and pre-eminent performing arts centre has successfully undergone open heart surgery to a critical electrical and business support asset: The upgrade of its main electrical switchboard.
As host to approximately 4 million visitors per year and the stage for almost 1550 performances annually, Sydney Opera House (SOH) is a very busy venue that relies on continuous operation of its services in order to deliver a flawless customer experience day after day, night after night. It’s fitting then, that the upgrade to a critical services asset involved an innovative approach from a dynamic company.
The Challenge
To comprehensively upgrade the 30 year old main electrical switchboard without disruption to any business units across SOH. The main electrical switchboard supporting SOH was at the end of its service life.
A conventional strategy to the switchboard upgrade would not have accommodated ongoing commercial and artistic contractual commitments: SOH could not shut down for several weeks to refurbish an asset. The original solution was to retro-fit each unit on-site with the power down. This approach was workable but concentrated most of the risk to on-site works with SOH powered down and vulnerable.
Access windows for the work were restricted to power outages of just 6 hours at a time, once a month.
Each shutdown and re-energisation event was a logistical and financial inconvenience and at this rate, the upgrade approach would take an estimated 36 power shutdowns over a period of 3 years! Major elements of the asset would be left unfinished and any alternative solution would have to address the location of existing sub-main circuits, the physical constraints of the site and the interfacing of new equipment with old construction techniques.
The Solution
Specialist technical expertise from Commercial Energy Services (CES) resulted in creative methodical solutions coupled with superior design detail and logistics management. Engaging Commercial Energy Services brought the application of thoroughly developed risk management and safety documentation sets and comprehensive client management services. CES proposed to conduct some investigation to make a better diagnosis and advise treatment.
Feasibility assessments resulted in CES coming back to SOH with an achievable and creative approach involving the off-site manufacture of switchboard sections and some precise engineering and logistics management. This solution removed most of the risk associated with the on-site upgrading of equipment with the power isolated. Quite ingeniously, any surprises could be confined to the manufacturing process and not the critical on-site works. The delivery of this strategy required a thorough understanding of the switchboard construction. While the design of new sections had to match the old sub-main
terminations, they also had to easily slide into the existing base structure.
That is, space had to be made for the installation by carefully dismantling and collapsing sections of the switchboard piece by piece. The CES solution was superior in its ability to eliminate risk and quality of the product, but also very challenging: significant time pressure would be placed on each 6 hour shutdown period.
The tooling and equipment on-site had to be the latest in portable technology. Critically, the planning, resources and risk management needed to be first-rate. Impressively, this method proposed to significantly limit impact to SOH and reduce the project to 2 years, a reduction of 66% on the initial timeframe proposed.
The Outcome
The engineering, upgrade strategies and technical solutions developed by CES removed major elements of identified risk from the project.
The project was compressed by 66% minimising impact on SOH. With CES on board, SOH successfully replaced all major elements of the 20 metre main electrical switchboard without interruption to any business units or operation.
The project solutions delivered by CES reduced risk, saved time, delivered worthwhile technological advancements and made the asset scalable for the future. CES’s comprehensive understanding of SOH business enabled the venue to execute this major maintenance project without compromising the enterprise, its brand or its profile.
CES provided a suite of risk mitigation measures for the project including the construction of a replica switchboard to train and familiarise CES staff on the existing SOH switchboard. This replica also enabled the CES method to be assessed in time and workability. A fully-equipped mobile workshop was deployed on-site to cater for all shutdowns as they were underway.
Looking ahead to the next 30 years, SOH can feel confident in fulfilling its aspirations: CES’ consultative approach has meant that all strategic building plans have been factored into the design of the switchboard. The asset will grow with the demands that the business places on it. The management of the system via custom software allows staff to easily monitor the switchboard and assess changes through reporting. As the focus on energy management and efficiency increases in Australia, SOH is well equipped to manage its future.
“The big advantage with Commercial Energy Services is their desire to listen and to understand our business. Couple that with their innovation and technical expertise, they become very important partners to our business.”
Paul Akhurst, Director of Facilities,
Sydney Opera House
