UGL’s industrial and resources team is driving a major upgrade project at Bayswater Power Station in the Hunter Valley, New South Wales - one of Australia’s key power generation sites.
As part of ongoing maintenance and upgrade programs, our team is replacing the four low-pressure (LP) heater vessels on Unit 4, including the drains cooler, to help ensure the station’s reliability. These heaters use low-pressure turbine steam to preheat condensate before it returns to the boiler, improving efficiency, reducing fuel use and emissions, and lowering boiler stress.
A key feature of the project was the dual-crane lift operation to remove two of the vessels. This complex and highly coordinated lift involved 120-tonne and 200-tonne cranes showcasing the expertise and teamwork of our on-site crew.
Beyond replacing vessels, the project includes other complex supporting scopes, such as:
- pipework removal, preparation, and reinstallation
- pressure welding and pipe fitting
- rigging and non-destructive testing (NDT)
- scaffolding, insulation, cladding, and electrical works.
The project workforce brings together experts in project management, quality, welding, fitting, rigging, confined spaces and health, safety, and environment — all working with a shared focus on safety, quality, and precision.
Two innovations are improving safety and efficiency:
- A custom rail system engineered by UGL’s Bennetts Green team for accurately moving LP vessels
- A magnetic floor protection system to prevent the risk of dropped objects and maintain site safety.
UGL's Bennetts Green workshop is recognised for delivering customised pressure equipment solutions for the oil, gas, and energy sectors.
A major project milestone has been achieved with the successful removal and transport of all LP vessels and the drains cooler, with new vessels now installed.
“This project shows what’s possible when experienced teams unite on safety, innovation, and quality,”said Jason Murray, UGL Project Manager.
UGL partners with Australia’s leading energy providers to extend the life of vital infrastructure through refurbishment, upgrades, and decommissioning services. Driven by collaboration, innovation, and technical expertise, we are proud to help power Australia’s energy future.