When it comes to complex engineering projects, the UGL team knows how to deliver. A recent upgrade at Millmerran Power Station in Queensland is a great example of smart thinking, skilled hands, and seamless teamwork.
The crew were tasked with replacing the ageing IP5 Heater – a 12-metre-long, 23-tonne heat exchanger that plays a key role in the power station’s operations. Located on the mezzanine level of the plant, the heater takes leftover steam from the turbine and uses it to heat water at the start of the energy cycle, improving overall efficiency.
The new heater was expertly fabricated at our Bennetts Green workshop in New South Wales, where a focus on quality and precision ensured a robust and reliable solution. Our integrated approach ensured consistency from initial concept through to final delivery.
Getting the new heater into place was no small feat. Due to its size and tricky location, the team had to get creative. Scott Sankey, UGL project manager for the upgrade shared, “After detailed planning and advanced modelling, we developed a custom rail system that allowed us to “skate”the heaters along a narrow path to a spot where an overhead gantry crane could reach. Because of the confined location, the methodology required the heater to be pivoted 22.5 degrees on the spot at the mid-point, this required careful consideration, engineering and design to achieve.”
This marks the second successful IP heater replacement completed at Millmerran Power Station, following a similar project delivered in 2024. Our repeat engagement highlights our reputation for delivering highly technical, large-scale solutions with precision and care.
By combining advanced planning, innovative engineering, and end-to-end delivery capability, UGL continues to support the reliable and efficient operation of critical energy infrastructure across Australia.
