Agl Solar Project Final Report

AGL Energy Solar
Project
Final Project Report
June 2019
Table of Contents
1. Introduction ............................................................................... 2
2. Outcomes .................................................................................. 4
3. Project Funding ........................................................................... 8
4. Funding Statement ...................................................................... 9
5. Project Milestones ..................................................................... 10
6. Knowledge Sharing.................................................................... 12
6.1. Knowledge Sharing – Engineering ................................................................................. 12
6.2. Knowledge Sharing – Regulatory ................................................................................... 13
6.3. Knowledge Sharing – Procurement ................................................................................ 13
6.4. Knowledge Sharing – Construction (Connection Works) ..................................................... 14
6.5. Knowledge Sharing – Construction (Solar Plant) ............................................................... 14
6.6. Knowledge Sharing – Commissioning............................................................................. 16
6.7. Knowledge Sharing – Operations and Maintenance ........................................................... 17
7. Publications .............................................................................. 18

Appendices........................................................................................ 19
A – Project Milestone Certificates ............................................................. 21
B –Knowledge Sharing Reports ............................................................... 22
C – Knowledge Sharing Certificates .......................................................... 23
D – Knowledge Sharing Workshop Presentation ........................................... 24
AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 1

1. Introduction
This report has been prepared to satisfy the Final Reporting requirements set out in Section 3
of Schedule 3 (Table 1) and Item 6(b) of Schedule 4 (Table 2) of the executed ARENA
Funding Agreement:
Table 1 – Final Report requirements

Requirement Description
(i) the name of the Recipient, Projectco and all their Recipient: AGL PV Solar Holdings Pty
subcontractors; Limited (ABN 88 158 007 660)
Projectco: AGL PV Solar Developments Pty
Limited (ABN 15 158 008 158)
Subcontractors: First Solar (Australia) Pty Ltd
(ABN 66 141 686 946)
Consolidated Power Projects
Australia Pty Ltd (CPP)
(ABN 18 075 411 219)
(ii) the Project title; AGL Energy Solar Project – Nyngan and Broken Hill
Solar Plants
(iii) the amount of Funds paid under the Agreement; Refer to Section 2 – Outcomes Project Funding
(iv) a statement of the Funds, Recipient Refer to Section 3 – Funding Statement

Contributions and Other Contributions received and
spent;
(v) the amount (if any) remaining in the account Refer to Section 3 – Funding Statement
referred to in clause 10.3;
(vi) a description and analysis of the progress of the Refer to the relevant sections of this report for the
Project, including: relevant description and analysis:
(A) evidence that the Project has been (A) Section 2 – Outcomes, and
completed, and the Project Milestones have Section 5 – Project Milestones;
been achieved;
(B) Section 2 – Outcomes; and
(B) details of the extent to which the Project Section 5 – Project Milestones;
achieved the Outcomes;
(C) Section 6 – Knowledge Sharing; and
(C) any highlights, breakthroughs or difficulties Section 7 – Publications; and
encountered; and
(D) Section 6 – Knowledge Sharing; and
(D) conclusions or recommendations (if any) Section 7 – Publications
arising from the Project; and
(vii) copies of any published reports, promotional Refer to Section 7 – Publications

material, media publicity, pamphlets or other
documentation relevant to the Project.

Table 2 – Final Knowledge Sharing Report requirements
Requirement Description
(i) all of the knowledge sharing activities A total of 38 reports were prepared covering most
completed as at final Project Milestone aspects of the project, including:
Notice Date and the End Date (as the case
may be);  Engineering
 Regulatory
 Procurement
 Construction (Connection Works)
 Construction (Solar Plant)
 Commissioning
 Operations and Maintenance
In addition, AGL presented lessons learned to the
ARENA Large Scale Solar Knowledge Sharing
Workshop on 22 April 2015.
These can be found in Section 6 – Knowledge
Sharing.
(ii) analysis of the effectiveness of each of the Each of the knowledge sharing reports included:
knowledge sharing activities so completed;
 A review of key lessons learned
 Analysis of the implications for future projects
 Analysis of any knowledge gaps, and
 Any relevant background information
These can be found in Section 6 – Knowledge
Sharing.
(iii) for any on-going knowledge sharing Not applicable

activities, an update of progress in
undertaking each knowledge sharing
activity; and
(iv) an assessment by Projectco of its success The original rationale for funding the AGL Energy
in achieving the Knowledge Sharing Solar Project was to gain knowledge “through the
Objective and the Knowledge Sharing construction and operation of large-scale, grid-
Outcomes. connected solar power stations (to) help solar energy
to play a bigger role in meeting Australia’s electricity
needs.”
The project aimed to “increase knowledge in large-
scale solar energy through the construction of two
solar photovoltaic (PV) power stations…”
ARENA’s press release on 22 June 2016, “Project
proposals show shrinking cost of big solar” showed
that this aim had been met.
Refer to Section 2 – Outcomes

2. Outcomes
As stated on the ARENA website (https://arena.gov.au/projects/agl-solar-project/), the ‘need’
for the AGL Energy Solar Project is, “Knowledge gained through the construction and
operation of large-scale, grid-connected solar power stations will help solar energy to play a
bigger role in meeting Australia’s electricity needs.”
The project aimed to “increase knowledge in large-scale solar energy through the construction
of two solar photovoltaic (PV) power stations…”
ARENA’s press release on 22 June 2016, “Project proposals show shrinking cost of big solar”
(https://arena.gov.au/news/project-proposals-show-shrinking-cost-of-big-solar/) showed that
this aim had been met.
Specifically, the AGL Energy Solar Project achieved all of the project outcomes set out in the
funding agreement, as tabulated below:
Table 3 – Outcomes
Project Outcome Description
a) construct and operate the solar power plants Nyngan solar plant (NYSP) achieved practical
which form part of the Project in accordance with completion on 7 June 2015, and Broken Hill solar
this Agreement to demonstrate that large scale plant (BHSP) achieved practical completion on
solar power plants can be constructed and 6 October 2015.
operated within major electricity grids in
Australia;
b) develop a commercially viable business model Refer to Section 6 – Knowledge Sharing, including:
for constructing and operating the solar power
plants which form part of the Project and  2D Definition of project scope between
generating and wholesaling electricity generated multiple contractors
by those plants; AGL found that engaging a single engineering,
procurement and construction contractor on a
project can reduce risks.
 3C Guide to engineering design and
procurement
The construction of a utility scale solar project
involves taking standard designs and localising
them to the local standards and codes, as well
to local site requirements. This involves co-
ordinating international design teams with local
subject matter experts to provide code
compliant designs for cost-effective
procurement and implementation.
 7B Maintenance
The location of the plant, the consequential
delays in access by service providers and the
availability of spares are critical in the

development of spares and maintenance
strategies, and what can be performed in house.
Also, refer to the AGL presentation to the ARENA
Large Scale Solar Knowledge Sharing Workshop on
22 April 2015.
c) develop and implement strategies for integrating Refer to Section 6 – Knowledge Sharing, including:
the energy generated by the solar power plants
which form part of the Project into the Recipient’s  2E Preparation of connection studies
renewable energy portfolio and managing that AGL learned that technical modelling and
renewable energy portfolio after integration; connection studies needed for grid connection
can be time consuming.
 4H Guide to gaining regulatory approvals for
large-scale solar projects in NSW
AGL developed this step by step guide to
provide a general framework which may help
reduce the time required to obtain planning
consents for future large-scale solar projects in
NSW.
 5E AEMO Generator Registration
Allow time and effort to educate stakeholders,
because each project will have its own
combination of supplier and model of inverter;
version of the NER rules; NSP; and contact
personnel.
 5F Grid connection – energisation
To ensure a smooth transition from installation
to the grid connection, it would be beneficial for
the EPC contractor to appoint a dedicated
protection system coordinator to interface
between AEMO, the NSP, and the protection
equipment manufacturers/ suppliers.
 5G Generator Performance Standards
Consider including responsibility for the final
technical studies and GPS within the scope of
the EPC contract. This would eliminate an
unnecessary interface between those preparing
the GPS and the supplier. It would also align
control and impact of changes to the inverters
with the responsible Contractor.
d) engage participants from Australian industry to Refer to Section 6 – Knowledge Sharing, including:
construct and Operate the solar power plants
which form part of the Project to the extent  3A Guide to local procurement
practicable (taking into account comparative The delivery of a utility scale solar project
pricing and capabilities) to promote the requires supply of equipment and materials from
development of the Australian industry’s skills numerous specialty and commodity suppliers.
and capabilities in constructing and operating The establishment of an in-country supply chain
large scale solar plants; was deemed the most effective way to support
project delivery at the scale of the Nyngan Solar
Plant project.

 4E Guide to local supply chain issues
Local supply chain is non-existent for standard
products in foreign markets (e.g. I-Beam posts
used in the USA could not be sourced in
Australia). For imported products, foreign
suppliers are often unfamiliar with Australia
Standards and sometimes with export
requirements. Imported products increase lead
time and shipping costs.
e) engage contractors, suppliers and personnel Refer to Section 6 – Knowledge Sharing, including:
from the regions surrounding the solar power
plants which form part of the Project to the extent  3A Guide to local procurement
practicable (taking into account comparative The delivery of a utility scale solar project
pricing and capabilities) to promote the requires supply of equipment and materials from
development of those regions; numerous specialty and commodity suppliers.
The establishment of an in-country supply chain
was deemed the most effective way to support
project delivery at the scale of the Nyngan Solar
Plant project.
 3B Guide to labour and accommodation
The construction of utility scale solar project
involves a significant amount of skilled and
unskilled labour. Site locations in regional areas
such as Nyngan are not always able to meet the
full labour requirements and non-local labour
must be sourced to add to the local workforce.
 5D Community Engagement
Similar to other large infrastructure projects, it is
critical that experienced community engagement
personnel are allocated to the project at an early
stage, and that efforts are co-ordinated between
the owner/ developer and the contractors –
particularly in developing a local employment
participation plan to help manage local
community employment expectations.
f) share knowledge regarding the Project in Refer to:

accordance with this Agreement to promote the
development of the solar power industry in  Section 6 – Knowledge Sharing
Australia; and A total of 38 reports were prepared covering
most aspects of the project, including:
 Engineering
 Regulatory
 Procurement
 Construction (Connection Works)
 Construction (Solar Plant)
 Commissioning
 Operations and Maintenance
In addition, AGL presented lessons learned to
the ARENA Large Scale Solar Knowledge
Sharing Workshop on 22 April 2015.

 Section 7 – Publications
In addition to the Knowledge Sharing reports
published by ARENA on its website, AGL has
published media releases, environmental
reports, communication with the community, and
visual media (video footage of the completed
plants) on its project websites.
g) contribute to the research infrastructure being Refer to knowledge sharing report:

developed, research carried out and higher
education programs operated by the EIF  2G Review of connection feasibility on the
Institution in accordance with the EIF Agreement UQ Gatton 3.3 MW photovoltaic array
to promote research infrastructure and research The University of Queensland found that the
in Australia relating to solar power generation. proposed Gatton photovoltaic array can be
connected to that grid at 11 kV, rather than 33
kV, reducing costs without significant impacts to
the network.

3. Project Funding
AGL PV Solar Development Pty Limited (AGL) constructed the 102 MW Nyngan Solar Plant
(NYSP) and the 53 MW Broken Hill Solar Plant (BHSP) with $166.7 million funding support
from the Australian Renewable Energy Agency (ARENA) and $64.9 million from the NSW
Government (NSW).
Table 4 – Project Funding

Description Amount ($)
ARENA Project Milestones - Nyngan 116,130,000
ARENA Project Milestones - Broken Hill 40,570,000
ARENA Knowledge Sharing Milestones 10,000,000
Total Funds paid by ARENA (excluding GST) 166,700,000

4. Funding Statement
A statement of funding received and spent under the Agreement is tabulated below.
Table 5 – Final Report requirements

Description Amount
Funds paid by ARENA 166,700,000
Recipient Contributions from AGL 194,744,830
Recipient Contributions from First Solar 10,249,728
Other Contributions from NSW State Government 64,940,000
Bank interest received net of bank fees 2,694,658
Total received 439,329,216
Broken Hill payments 152,153,877
Nyngan payments 288,433,994
Total spent 440,587,871
Total amount remaining1 -
1
Requirement 3(a)(v): amount remaining in the account referred to in clause 10.3 is nil.

5. Project Milestones
Project Milestones formed the basis for the provision of the project funding shown in section 2
of this report. These Project Milestones, Project Milestone Dates and Funds are provided in
Section 2 of Schedule 5 of the ARENA Funding Agreement, and summarised in Table and
Table .
Table 6 – Summary of Project Funding Milestones – Broken Hill

Milestone Project Milestone
Milestone Date Certified
BH1 – Financial Close EPC Contractor module reservation 31 Jul 2013 22 Aug 2013
payment
BH2 – Execution of TransGrid’s Stage 3 Connection Investigation 31 Jul 2013 13 Aug 2013
and Negotiation Agreement
BH3 – Preliminary engineering design review complete 15 Oct 2013 18 Dec 2013
BH4 – Connection Agreement executed 31 Oct 2013 6 Dec 2013
BH5 – Procurement: order place for post and mounting hardware 30 Nov 2013 6 Jan 2014
BH6 – Detailed engineering design review complete 31 Dec 2013 19 Mar 2014
BH7 – Site mobilisation 15 Jul 2014 26 Aug 2014
BH8 – 25% of posts/ tilt brackets installed 31 Oct 2014 11 Mar 2015
BH9 – 50% of posts/ tilt brackets installed 31 Jan 2015 11 Mar 2015
BH10 – Practical Completion of all Sections 31 Oct 2015 16 Dec 2015
BH11 – Operation of Solar Power Station (NSW Funding 30 Apr 2016 24 May 2016
Agreement)
In accordance with clause 13 of the ARENA Funding Agreement all Project Milestones were
required to be certified by the Independent Certifier, Hyder Consulting Pty Limited (Hyder).
Copies of these Project Milestone Certificates for Broken Hill are provided in Appendix A.
Please note that Hyder changed their name Arcadis Australia Pacific Pty Ltd towards the end
of the AGL Energy Solar Project.

Table 7 – Summary of Project Funding Milestones – Nyngan
Milestone Project Milestone
Milestone Date Certified
NY1 – Financial Close EPC Contractor module reservation 31 Jul 2013 22 Aug 2013
payment
NY2 – Receipt of Essential Energy Offer to Connect 31 Jul 2013 13 Aug 2013
NY3 – Preliminary engineering design review complete 31 Aug 2013 27 Sep 2013
NY4 – Procurement: order place for post and mounting hardware 30 Nov 2013 18 Dec 2013
NY5 – Detailed engineering design review complete 31 Oct 2013 17 Feb 2014
NY6 – Connection Agreement executed 30 Nov 2013 27 Mar 2014
NY7 – Site mobilisation 28 Feb 2014 1 May 2014
NY8 – 25% of posts/ tilt brackets installed 30 Jun 2014 28 Aug 2014
NY9 – 50% of posts/ tilt brackets installed 30 Sep 2014 29 Oct 2014
NY10 – Practical Completion of all Sections 30 Jun 2015 29 Sep 2015
NY11 – Operation of Solar Power Station (NSW Funding 30 Apr 2016 26 May 2016
Agreement)
In accordance with clause 13 of the ARENA Funding Agreement all Project Milestones were
required to be certified by the Independent Certifier, Hyder Consulting Pty Limited (Hyder).
Copies of these Project Milestone Certificates for Nyngan are provided in Appendix A. Please
note that Hyder changed their name Arcadis Australia Pacific Pty Ltd towards the end of the
AGL Energy Solar Project.

6. Knowledge Sharing
As part of the ARENA funding requirements a series of Knowledge Sharing reports were
prepared and submitted. This series of reports describes lessons learned from most aspects
of the project’s delivery and are published under the Reports and Guides section of the Project
on the AGL Solar Project page on the ARENA website (https://arena.gov.au/projects/agl-solar-
project/) and reproduced in Appendix B.
In accordance with clause 14 of the ARENA Funding Agreement, achievement of the
Knowledge Sharing Milestones is confirmed through the provision of the Knowledge Sharing
Milestone Certificates which were issued by ARENA and are included in Appendix C of this
report.
Additionally, AGL participated in the ARENA Large Scale Solar Knowledge Sharing Workshop
on 22 April 2015 and provided a presentation which is included in Appendix D.
6.1. Knowledge Sharing – Engineering
2A Grid connection modelling to define solar plant performance characteristics

AGL used extensive modelling to determine the requirements of connecting its solar plant to
the grid.
2B Defining communications requirements for a new generator

AGL found that the cost of communications infrastructure between the generation facility,
Network Service Provider and Australian Energy Market Operator should be included in the
grid connection process.
2C Grid connection modelling and inverter characteristics

AGL shares its learning on the importance of using an appropriate plant invertor in grid
connection modelling.
2F Impact of temperature on plant performance and overhead line design

AGL found that savings can be made in the design of overhead transmission lines.
2G Review of connection feasibility on the UQ Gatton 3.3 MW photovoltaic array

The University of Queensland found that the proposed Gatton photovoltaic array can be
connected to that grid at 11 kV, rather than 33 kV, reducing costs without significant impacts to
the network.
3C Guide to engineering design and procurement

The construction of a utility scale solar project involves taking standard designs and localising
them to the local standards and codes, as well to local site requirements. This involves co-
ordinating international design teams with local subject matter experts to provide code
compliant designs for cost-effective procurement and implementation.

4D Guide to international knowledge transfer
Australia has minimal experience in the delivery of utility scale solar projects and has the
potential to benefit greatly from knowledge transfer from more developed international
markets, particularly Europe and North America.
6.2. Knowledge Sharing – Regulatory
2E Preparation of connection studies

AGL learned that technical modelling and connection studies needed for grid connection can
be time consuming.
4H Guide to gaining regulatory approvals for large-scale solar projects in NSW

AGL developed this step by step guide to provide a general framework which may help reduce
the time required to obtain planning consents for future large-scale solar projects in NSW.
5E AEMO Generator Registration

Allow time and effort to educate stakeholders, because each project will have its own
combination of supplier and model of inverter; version of the NER rules; NSP; and contact
personnel.
5F Grid connection – energisation

To ensure a smooth transition from installation to the grid connection, it would be beneficial for
the EPC contractor to appoint a dedicated protection system coordinator to interface between
AEMO, the NSP, and the protection equipment manufacturers/ suppliers.
5G Generator Performance Standards

Consider including responsibility for the final technical studies and GPS within the scope of the
EPC contract. This would eliminate an unnecessary interface between those preparing the
GPS and the supplier. It would also align control and impact of changes to the inverters with
the responsible Contractor.
6.3. Knowledge Sharing – Procurement
2D Definition of project scope between multiple contractors

AGL found that engaging a single engineering, procurement and construction contractor on a
project can reduce risks.
3A Guide to local procurement

The delivery of a utility scale solar project requires supply of equipment and materials from
numerous specialty and commodity suppliers. The establishment of an in-country supply chain
was deemed the most effective way to support project delivery at the scale of the Nyngan
Solar Plant project.

3B Guide to labour and accommodation
The construction of utility scale solar project involves a significant amount of skilled and
unskilled labour. Site locations in regional areas such as Nyngan are not always able to meet
the full labour requirements and non-local labour must be sourced to add to the local
workforce.
4C Guide to materials delivery

Opportunities for cost reduction exist in the optimisation of material delivery specifically
through the evaluation of multiple delivery points (Adelaide vs. Sydney) and form of transport
(road vs. rail). It is also important to monitor the existing transport networks to maximise
regional transport hubs.
4E Guide to local supply chain issues

Local supply chain is non-existent for standard products in foreign markets (e.g. I-Beam posts
used in the USA could not be sourced in Australia). For imported products, foreign suppliers
are often unfamiliar with Australia Standards and sometimes with export requirements.
Imported products increase lead time and shipping costs.
6.4. Knowledge Sharing – Construction (Connection Works)
4F Guide to switchyard construction

The construction of electrical infrastructure (e.g. substations, switchyards, or overhead lines)
assets needs to consider the specific requirements of the Network Service Provider (NSP) as
the ultimate owner of these assets. Essential Energy is the NSP for the Nyngan Solar Plant.
4G Guide to transmission easement

Construction of a utility scale solar project in regional Australia will typically require the
construction of a transmission line in order to connect the solar plant to the grid. Construction
and operation of the transmission line will require the creation of an easement in order to
provide a registered legal right that applies over the land. This process needs to consider the
specific requirements of the Network Services Provider (NSP) Essential Energy for the
Nyngan Solar Plant and other landholders.
6.5. Knowledge Sharing – Construction (Solar Plant)
3D Guide to early works activities

A number of early works activities were required to enable site mobilisation and facilitate the
commencement of construction at the Nyngan Solar Plant site. These activities included
upgrades to the site access turnoff and access road, initial earthworks, and construction of a
temporary water supply for dust suppression.
4A Guide to site mobilisation

The majority of the key learning’s involved in site mobilisation were driven by identifying and
engaging regional companies to provide the site mobilisation services. A number of capable

and experienced local players were identified in this space, and while none of the companies
had solar project experience the site mobilisation process is consistent with non-solar projects
and no major issues or gaps were identified.
4B Guide to access road construction

Thorough preparation and execution of the access road works is important to ensure timely
delivery of the project. Any delays in delivery (i.e. weather) will impact the project delivery
schedule as the majority of site works occur after the completion of the access road.
5A Civil works
Installation of weather‐proof access roads should be prioritised at the project start in order to
avoid delayed or out of sequence delivery of equipment and materials, and potential for civils
re‐work due to local rains.
Upfront design work on mounting structures and layout to consider the local topography of the
site can result in significant cost savings associated with civil works.
5B Structural works
There is significant value in upfront planning with respect to transportation logistics, for the
direct delivery of There is great value in upfront planning with respect to transportation
logistics, including planning for direct delivery of equipment to work zones to increase
efficiency of installation and reduced internal transportation requirements.
Improvements can be made in sequencing and planning of the structural and electrical works
such that the two works packages can proceed simultaneously, without obstructing access to
any of the work areas.
5C Electrical works, including solar PV module installation

There is significant value in upfront planning with respect to transportation logistics, for the
direct delivery of There is great value in upfront planning with respect to transportation
logistics, including planning for direct delivery of equipment to work zones to increase
efficiency of installation and reduced internal transportation requirements.
Improvements can be made in sequencing and planning of the structural and electrical works
Module installation work methods to increase installation efficiency and quality can be carried
through to future projects, including installation tooling, work staging and ergonomic
assistance.
Ensure access to materials throughout the build, given trenching and natural topographical
features, to allow work to progress along multiple fronts.
5D Community Engagement
Similar to other large infrastructure projects, it is critical that experienced community
engagement personnel are allocated to the project at an early stage, and that efforts are co-
ordinated between the owner/ developer and the contractors – particularly in developing a

local employment participation plan to help manage local community employment
expectations.
6H Demobilisation
Demobilisation for a solar project is identical to other construction projects.
6.6. Knowledge Sharing – Commissioning
6A Operating Protocol with Network Service Provider (NSP)

The Operating Protocols need to be finalised prior to the commencement of operations.
Discuss the process for developing the Operating Protocol with the NSP and their timing
expectations well in advance of generator completion.
6B SCADA and communications

In order to take advantage of key learnings, it is important to maintain consistency in SCADA
system design. This leads to efficiency not only in commissioning, but also in operation.
6C Commissioning of Inverters
Ideally the inverter’s complete firmware parameter list should be submitted as an attachment
to the R1 data, along with a map to corresponding model settings. This will help to ensure
consistency between the simulation and actual plant performance, and reduce the risk of
needing to make adjustments to the inverter settings later in the commissioning.
6D Commissioning of PVCS and PVIS

A key lesson learned was that changes to the Generator Performance Standards (GPS) that
impact the inverter protection will also impact the PVCS protection schemes, and that this can
have a significant project impact through the need to coordinate with third parties to revise and
test relay protection settings.
6E Coordination with NSP during Commissioning Generation

The commissioning plan and test procedures should: be developed in cooperation with the
NSP at least 3 months prior to commissioning; identify all activities that involve the NSP; aim
to schedule dates for these activities at least 1 month in advance; allow for the unpredictable
nature of commissioning
6F Commissioning of Generating System to AEMO Requirements

This phase of the project can have significant impact on project timelines and should receive
appropriate attention from the outset. This would include holding detailed design review
meetings with the NSP and AEMO during the modelling stage of the project, to ensure
consistency between the Generator Performance Standards and the intended design of the
plant.
6G Minimum Capacity Test

The test procedure used for determining the minimum capacity of the plant should be agreed
between the owner/ developer and the Principal Contractor and appended to the contract.

6.7. Knowledge Sharing – Operations and Maintenance
7A Recruitment of Operators
Given the absence of experienced operators and third-party providers of solar plant operator
training, the burden of training operators will fall on the plant’s operators. There are significant
benefits to recruiting from among personnel involved in the commissioning of the plant, or
involving candidate operators in the commissioning of the plant.
7B Maintenance
The location of the plant, the consequential delays in access by service providers and the
availability of spares are critical in the development of spares and maintenance strategies, and
what can be performed in house.
7C Operation
Monitoring for operational and reporting requirements needs to be considered as part of the
design.
7D Operability and maintainability
It is important to consider the needs of operations and maintenance staff in the design of the
plant, particularly: safe, easy, all-weather access to equipment for routine operations or
maintenance activities.

7. Publications
The AGL Solar Project page on the ARENA website (https://arena.gov.au/projects/agl-solar-
project/) provides a rationale for the project, access to the series of Knowledge Sharing reports
described above, and links to various media releases.
The AGL’s project website the Nyngan Solar Plant and Broken Hill Solar Plant includes media
releases, environmental reports, communication with the community, and visual media (video
footage of the completed plants)
 NYSP: www.agl.com.au/about-agl/how-we-source-energy/renewable-energy/nyngan-
solar-plant
 BHSP: www.agl.com.au/about-agl/how-we-source-energy/renewable-energy/broken-
hill-solar-plant

Appendices
A Project Milestone Certificates
B Knowledge Sharing Reports

Engineering
2A Grid connection modelling to define solar plant performance characteristics
2B Defining communications requirements for a new generator
2C Grid connection modelling and inverter characteristics
2F Impact of temperature on plant performance and overhead line design
2G Review of connection feasibility on the UQ Gatton 3.3 MW photovoltaic array
3C Guide to engineering design and procurement
4D Guide to international knowledge transfer
Regulatory
2E Preparation of connection studies
4H Guide to gaining regulatory approvals for large-scale solar projects in NSW
5E AEMO Generator Registration
5F Grid connection – energisation
5G Generator Performance Standards
Procurement
2D Definition of project scope between multiple contractors
3A Guide to local procurement
3B Guide to labour and accommodation
4C Guide to materials delivery
4E Guide to local supply chain issues
Construction (Connection Works)

4F Guide to switchyard construction
4G Guide to transmission easement
Construction (Solar Plant)

3D Guide to early works activities
4A Guide to site mobilisation
4B Guide to access road construction
5A Civil works

5B Structural works
5C Electrical works, including solar PV module installation
5D Community Engagement
6H Demobilisation
Commissioning
Operations and Maintenance

7B Maintenance
7C Operation
C Knowledge Sharing Certificates
D Knowledge Sharing Workshop Presentation

A – Project Milestone Certificates

Hyder Consulting Pty Ltd
Level 5, 141 Walker Street
Locked Bag 6503
North Sydney NSW 2060
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
www.hyderconsulting.com
th
18 December 2013
TO:
Adrian Rule
Manager, Large-Scale Solar Energy
Email: adrian.rule@arena.gov.au
Tom Grosskopf
Director, Metro Branch
Office of Environment and Heritage
Email: tom.grosskopf@environment.nsw.gov.au
Mark Stephens
Head of Construction Development,
Power Development, AGL Energy
Email: mstephens@agl.com.au
PROJECT MILESTONE CERTIFICATE FOR PROJECT MILESTONES BH3 UNDER ARENA AND
NSW FUNDING AGREEMENTS
Dear Mark, Adrian and Tom
In accordance with Clause 8.2(1) of the IC Agreement, upon a Project Milestone being achieved, and
within 5 Business Days after a request by Projectco, the Independent Certifier must provide ARENA,
NSW and the Recipient Parties with a Project Milestone Certificate for that Project Milestone.
The Independent Certifier received a request from Projectco to provide a Project Milestone Certificate
for Project Milestone BH3 under the ARENA Funding Agreement and NSW Funding Agreement on
th
11 December 2013.
The requirements for the Project Milestone are the same under the ARENA Funding Agreement and
NSW Funding Agreement, and are extracted in Table 1 below.
ARENA FUNDING AGREEMENT
BH3 – Preliminary Design review at 20% stage completed and Owner’s Engineer comments
engineering design review documented and transmitted to EPC Contractor. The 20% stage comprises
complete documentation of the project specifications for transformers, inverters, PVIS,
PVCS, and electrical cable, and completion of an electrical single line diagram
and plant layout diagram.
Table 1: Description of Project Milestone BH3
Registered office: Level 5, 141 Walker Street, North Sydney NSW 2060, Australia ABN 76 104 485 289
IC Certificate Of Project Milestone Completion BH3

Projectco provided the following documentation to The Independent Certifier as evidence supporting
its view that Project Milestone BH3 has been achieved:
• 20% design drawings (electrical and plant layout)

• 20% design specifications and data sheets for transformers, inverters, PVIS, PVCS and
electrical cable
• Owner's Engineer (SKM) review and transmittal of comments to the EPC Contractor
The Independent Certifier has reviewed Projectco’s request, and the supporting information provided
with it, and is of the professional opinion that Project Milestone BH3 has been achieved in full under
the ARENA Funding Agreement and NSW Funding Agreement.
Accordingly, the Independent Certifier issues this Project Milestone Certificate in accordance with
clause 8.2(1) of the Independent Certifier Agreement for Project Milestone BH3 under the ARENA
Funding Agreement and NSW Funding Agreement.
In this letter:
(a) “Independent Certifier Agreement” means the Independent Certifier Agreement dated 26 July
2013 between Australian Renewable Energy Agency, the Minister for the Environment for and
on behalf of the Crown in right of the State of New South Wales, AGL PV Solar Holdings Pty
Limited, AGL PV Solar Developments Pty Limited and Hyder Consulting Pty Limited.
(b) capitalised terms that are defined in the IC Agreement have the same meaning.
Yours sincerely
Anthony Venturini
Director Property Energy Services
+61 2 8907 9000
[CC: Doug Landfear, Ghulam Amur]
IC Certificate Of Project Milestone Completion BH3 Page 2

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
6 December 2013
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
PROJECT MILESTONE CERTIFICATE FOR PROJECT MILESTONE BH4 UNDER ARENA AND
for Project Milestone BH4 under the ARENA Funding Agreement and NSW Funding Agreement on 2
December 2013.
BH4 TransGrid and Projectco execute an agreement or agreements for the

connection of the power station to the network

Projecto provided the following documentation to The Independent Certifier as evidence supporting its
view that Project Milestone BH4 has been achieved:
 Letter from TransGrid dated 15 November 2013

 Executed "Project Agreement for the Broken Hill Solar PV Station
 Executed "Generator Connection Agreement for the Broken Hill Solar PV Station
 Executed Deed of limitation and exclusion of liability
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000
[CC: Doug Landfear, Henry Adams, Penny Kalaremas]

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
6 January 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
PROJECT MILESTONE CERTIFICATE FOR PROJECT MILESTONES BH5 UNDER ARENA AND
th
30 December 2013.
BH5 – Procurement: Orders Evidence provided by EPC Contractor that it has placed order for posts, tilt
placed for post and brackets and fasteners
mounting hardware

its view that Project Milestone BH5 has been achieved:
 Posts - PO 4600049334 FSE California - EPC.pdf
 Tilt brackets - PO 4800016988 Hofmann Engineering Pty Ltd.pdf
 Fasteners - PO 4800016987 Southwest Fastener.pdf
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
19 March 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
th
Wednesday 12 March 2014.
BH6 – Detailed Engineering Design review process at 90% stage completed and Owners Engineer comments
Review documented and transmitted to EPC Contractor. The 90% stage is complete and
design for site civil works (including perimeter fencing); module support design;
electrical design including PVIS, PVCS, PCS, transformers, combiner boxes and
SCADA system; and temporary construction office layout. Vendor drawings
associated with the above components, and the O&M building, are excluded
from the 90% stage.

Projectco provided the following documentation via Aconex to The Independent Certifier as evidence
supporting its view that Project Milestone BH6 has been achieved:
 Aconex General Correspondence: AGLE-GCOR-000077
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
26 August 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
nd
Friday 22 August 2014.
BH7 – Site Mobilisation Broken Hill EPC Contract requirements for site mobilisation satisfied, including
H&S Plan, Environmental Management Plan and necessary insurances

supporting its view that Project Milestone BH7 has been achieved:
• Aconex General Correspondence: General Correspondence: SKM-GCOR-000141
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
18 December 2013
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
PROJECT MILESTONE CERTIFICATE FOR PROJECT MILESTONES NY4 UNDER ARENA AND
for Project Milestone NY4 under the ARENA Funding Agreement and NSW Funding Agreement on
th
16 December 2013.
NY4 – Procurement: Orders Evidence provided by EPC Contractor that it has placed order for posts, tilt
placed for post and brackets and fasteners
mounting hardware
Table 1: Description of Project Milestone NY4
IC Certificate Of Project Milestone Completion NY4

its view that Project Milestone NY4 has been achieved:
 Posts - PO 4600049193 FSE California - EPC.pdf
 Tilt brackets - PO 4800016644 Hofmann Engineering Pty Ltd.pdf
 Fasteners - PO 4800016484 Southwest Fastener.pdf
with it, and is of the professional opinion that Project Milestone NY4 has been achieved in full under
clause 8.2(1) of the Independent Certifier Agreement for Project Milestone NY4 under the ARENA
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000
IC Certificate Of Project Milestone Completion NY4 Page 2

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
17 February 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
PROJECT MILESTONE CERTIFICATE FOR PROJECT MILESTONE NY5 UNDER ARENA AND
th
Monday 10 February 2014.
NY5 – Detailed Engineering Design review process at 90% stage completed and Owners Engineer comments
Review documented and transmitted to EPC Contractor. The 90% stage is complete and
design for site civil works (including perimeter fencing); module support design;
electrical design including PVIS, PVCS, PCS, transformers, combiner boxes and
SCADA system; and temporary construction office layout. Vendor drawings
associated with the above components, and the O&M building, are excluded
from the 90% stage.

supporting its view that Project Milestone NY5 has been achieved:
 Aconex General Correspondence: AGL-GCOR-000406
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
27 March 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
st
Friday 21 March 2014.
NY6 – Connection Essential Energy and Projectco execute an agreement or agreements for the
Agreement Executed connection of the power station to the network

• Aconex General Correspondence: AGL-GCOR-000481
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
st
1 May 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
th
Monday 28 April 2014.
NY7 – Site Mobilisation Nyngan EPC Contract requirements for site mobilisation satisfied, including H&S
Plan, Environmental Management Plan and necessary insurances

• Aconex General Correspondence: AGL-GCOR-000561 and AGL-GCOR-000568
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
th
28 August 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
th
Thursday 28 August 2014.
NY8 – 25% of posts/tilt 25% of posts and tilt brackets installed and available for verification (minor
brackets installed outstanding items permitted)

• General Correspondence - SKM-GCOR-000711 (Quality Records)
• Site inspection undertaken by Hyder on 27/8/2014
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Locked Bag 6503
Australia
Tel: +61 2 8907 9000
Fax: +61 2 8907 9001
29th October 2014
TO:
Adrian Rule
Tom Grosskopf
Mark Stephens
Tuesday 28th October 2014.
NY9 – 50% of posts/tilt 50% of posts and tilt brackets installed and available for verification (minor
brackets installed outstanding items permitted)

• Site inspection undertaken by Hyder on 28/10/2014
In this letter:
Yours sincerely
Anthony Venturini
+61 2 8907 9000

Adrian Rule Arcadis Australia Pacific Pty Ltd
Manager, Large-Scale Solar Energy Level 5, 141 Walker Street
Locked Bag 6503
NORTH SYDNEY NSW 2060
Tel No: +61 2 8907 9000
Tom Grosskopf Fax No: +61 2 8907 9001
Director, Metro Branch arcadis.com
Mark Stephens
29 September 2015
PROJECT MILESTONE CERTIFICATE FOR PROJECT MILESTONE NY10

UNDER ARENA AND NSW FUNDING AGREEMENTS

In accordance with Clause 8.2(1) of the IC Agreement, upon a Project Milestone being
achieved, and within 5 Business Days after a request by Projectco, the Independent
Certifier must provide ARENA, NSW and the Recipient Parties with a Project Milestone
Certificate for that Project Milestone.
The Independent Certifier received a request from Projectco to provide a Project

Milestone Certificate for Project Milestone NY10 under the ARENA Funding Agreement
and NSW Funding Agreement on Friday, 25 September 2016.
The requirements for the Project Milestone NY10 according to the ARENA Funding
Agreement and NSW Funding Agreement are extracted in Table 1 & Table 2 below.
NY10 – Practical Certificates of Practical Completion for all sections issued to EPC
Completion of all Contractor under the EPC Contract.
Sections
F:\AA006145\D-Calculations\STS - MILESTONES\Certificate for Milestones NY10\IC Certificate of Project

Milestone Completion NY10 (3).docx
NSW FUNDING AGREEMENT
Certificates of Practical Completion for all sections issued to EPC

Contractor under the EPC Contract.
NY10 – Practical
Reports provided by EPC Contractor which demonstrate that the
Completion of all
combined capacity of Sections 1, 2, 3 & 4 determined in accordance
Sections
with Schedule 13 of the Nyngan EPC Contract is at least 95% of
102.06MWac.
Projectco provided the following documentation via Aconex to The Independent Certifier
as evidence supporting its view that Project Milestone NY10 has been achieved:
• Response to RFI - SKM-RTRFI-000032 (Quality Records)
• Advice - SKM-ADVICE-000248 (Quality Records)
• Site inspection undertaken by Arcadis on 15/09/2015
The Independent Certifier has reviewed Projectco’s request, and the supporting
information provided with it, and is of the professional opinion that Project Milestone
NY10 has been achieved in full under the ARENA Funding Agreement and NSW
Funding Agreement.
Accordingly, the Independent Certifier issues this Project Milestone Certificate in
accordance with clause 8.2(1) of the Independent Certifier Agreement for Project
Milestone NY10 under the ARENA Funding Agreement and NSW Funding Agreement.
In this letter:
(a) “Independent Certifier Agreement” means the Independent Certifier Agreement

dated 26 July 2013 between Australian Renewable Energy Agency, the Minister
for the Environment for and on behalf of the Crown in right of the State of New
South Wales, AGL PV Solar Holdings Pty Limited, AGL PV Solar Developments
Pty Limited and Arcadis Australia Pacific Pty Limited (incorporating Hyder
Consulting Pty Limited)
F:\AA006145\D-Calculations\STS - MILESTONES\Certificate for Milestones NY10\IC Certificate of Project 2

Yours sincerely
pp Anthony Venturini
+61 2 8907 9000
CC: Doug Landfear, Ghulam Amur
F:\AA006145\D-Calculations\STS - MILESTONES\Certificate for Milestones NY10\IC Certificate of Project 3

B –Knowledge Sharing Reports

Grid connection modelling to define solar
plant performance characteristics 2A
Knowledge type: Network connections
Technology: Solar photovoltaic
Key learning
Negotiating a grid connection with a Network Service Provider (NSP) is technically and commercially
challenging. Defining the technical characteristics of the solar plant and determining how the plant
will interact with the network during fault events may require extensive, iterative modelling.
Implications for future projects

For new grid connections, it is essential to engage early and often with the relevant NSP to define
the commercial and technical requirements for grid connection. The developer may want to
establish a program of regular meetings with the NSP to review the progress of technical studies and
define commercial arrangements.
Knowledge gap
There is a need for data to demonstrate the impacts of large-scale solar plants on the Australian
electrical network. The Australian Energy market Operator (AEMO) may be able to facilitate
development of this knowledge through knowledge gained during development and operation of
the Broken Hill and Nyngan Solar Plants.
Background
Objectives or project requirements
AGL worked with Essential Energy to define the requirements for connecting into the Essential
Energy network at Nyngan. A key technical and commercial issue was defining the amount and
location of additional reactive plant, which would be required to support the network in the event of
voltage collapse.
Process undertaken
AGL conducted detailed modelling of the grid network to determine the amount of additional
reactive capacity that would be required in the network, based on the operating characteristics of
the solar plant – in particular the inverters used to convert the direct current produced by the
plant’s photovoltaic modules to alternating current. AGL was able to demonstrate, through multiple
connection studies, that 4 MVAr of dynamic reactive plant installed at the Essential Energy Nyngan
Substation would be sufficient to stabilise network voltage in the event of a fault on the network
between Nyngan and Dubbo (refer Figure 1).
1 AGL Energy Solar Project (Nyngan and Broken Hill Solar Plants)
Supporting information
Figure 1 shows the sub-transmission network supplying Dubbo, Nyngan and Cobar from
TransGrid’s Wellington 330/132kV substation. The diagram shows locations and capacities of
substations and the transmission and sub-transmission lines owned and operated by TransGrid and
Essential Energy. Cities and towns are shown.
Figure 1 – Existing Essential Energy western area sub-transmission network.

Source: Essential Energy, 2012. Consultation Information Report – Augmentation of Electricity Supply
to Dubbo and the Western Area of NSW.
Defining communications requirements for a
new generator 2B
Knowledge category: Technical
Key learning
Defining communications requirements between the generation facility and the Network Service
Provider (NSP) and Australian Energy Market Operator (AEMO) is a critical part of the grid
connection process.

It is essential to understand the physical infrastructure required to carry signals and communications
between the generation facility and AEMO. The cost of such infrastructure needs to be incorporated
in the project financial model and technical specifications need to be developed for the project
engineering, procurement and construction contractor.
Knowledge gap
It would be useful if there was information available that broadly defined the existing
communications infrastructure for each part of the National Electricity Market and specified the
technical requirements for grid communications for various types and sizes of generation facility.
Background
A significant issue for the Broken Hill Solar Plant was the need for upgrades to communications
infrastructure to support both the solar project and the Silverton Wind Farm, which AGL is also
developing and which will share the same connection point. Determining the best solution for the
solar project required extensive discussion and negotiation with the NSP (TransGrid).
Process undertaken
AGL worked closely with TransGrid to define the existing communications infrastructure and the
need for upgrades to communications services. TransGrid identified required upgrades to microwave
and fibre optic systems, as well as communications links within existing substations. In total, over
1,700km of communication bearers were needed to provide compliant communication services for
both the solar and wind projects. However, AGL and TransGrid agreed on significantly reduced
communications requirements for the solar project, which is being built first. Further upgrades will
likely be required in the future as part of the wind farm development.
Figure 1 shows a conceptual diagram of the communications assets and services upgrades
potentially required to support both the Broken Hill Solar Plant and the proposed Silverton Wind
Farm. AGL and TransGrid defined a smaller package of upgrades to support the solar project alone.
Grid connection modelling and inverter
characteristics 2C
Key learning
The performance characteristics of the plant inverters are a key input to grid connection modelling
conducted for a solar plant. The grid connection model, which forms the basis of the Connection
Study and the Connection Agreement, needs to be based on a particular inverter make and model.

It is advisable to definitively select an inverter model before conducting grid connection studies.
Otherwise, the technical modelling for the connection studies may need to be redone and the
project will incur additional time and cost.
Knowledge gap
It could be useful to establish links between Network Service Providers (NSPs) and major inverter
manufacturers so that inverter performance models can be made readily available in the correct
software format. This would facilitate preparation of grid connection studies and discussions
between project developers and NSPs.
Background
As project proponent, AGL conducted technical modelling to support preparation of connection
studies for the Nyngan and Broken Hill projects. The modelling used proprietary software, which
requires specification of inverter settings and network characteristics to determine the expected
impacts of a generation facility on the network. The results of the modelling were incorporated into
connection studies, which were used to negotiate the commercial and technical arrangements
between the project proponent and the NSP.
Process undertaken
As the engineering, procurement and construction contractor for the projects, First Solar was
responsible for selecting the inverter make and model to be used in the solar plants. Unfortunately,
First Solar elected to use a different inverter than the one that AGL had used in the earlier
connection studies. Because the performance characteristics of the two inverters were slightly
different, AGL was required to redo the technical modelling to define plant performance. AGL
engaged a technical consultant to conduct the grid modelling, and this additional modelling incurred
extra cost as well as a delay in finalising project connection arrangements.
Impact of temperature on plant performance and
overhead line design 2F
Knowledge type: Technology
Key learning
The design of overhead transmission lines must take into account the maximum ambient temperature that
determines conductor sag (and therefore pole/line height requirements). Transmission lines are also designed to
take into account maximum expected current (in this case, the current generated by the solar plant).
While it would be reasonable to assume that peak solar plant output would occur during periods of high solar
radiation (which would imply high ambient temperatures), due to the thermal de-rating of photovoltaic (PV)
modules with temperature, it is unlikely that the peak output of a solar plant will occur at the same time as the
maximum ambient temperature. As a result, overhead transmission lines may not need to be designed for the
condition in which peak plant output and maximum ambient temperature occurs at the same time.

When designing overhead transmission lines for future solar projects, it may be possible to reduce the pole height,
which would be determined from a conservative calculation of maximum ambient temperature and maximum plant
output. This may result in reduced construction costs for overhead transmission lines.
Background
AGL engaged an engineering, procurement and construction (EPC) contractor to design and construct the overhead
transmission lines for the Nyngan Solar Plant. In addition, AGL engaged a technical consultant to review the EPC
contractor’s engineering design calculations and drawings. These calculations and drawings were also reviewed with
the relevant Network Service Provider and regulatory authorities.
Process undertaken
For the Nyngan project, the EPC contractor submitted preliminary engineering design drawings and calculations to
AGL. Through the process of engineering design and safety review, AGL and its technical consultant identified that
the proposed design height of the transmission lines took into account both maximum ambient temperature and the
maximum expected output of the solar plants. However, further calculations demonstrated that, due to the
expected thermal de-rating of PV modules with increasing temperature, the maximum plant output was unlikely to
occur at the same time as maximum ambient temperature. As such, it was determined that the design pole heights
for Nyngan could be safely reduced, resulting in a small cost savings.
A review of connection feasibility on the UQ
Gatton 3.3 MW photovoltaic array 2G
Key learning
A connection feasibility study demonstrated that connection of the proposed 3.3 MW Gatton
photovoltaic (PV) array at 11 kV will not have significant technical impacts to the network, and will
be significantly cheaper than connection at 33 kV.

The Gatton project will facilitate collaboration between the University of Queensland (UQ) and
Energex (the Network Service Provider) in the study of distribution network impacts from medium-
scale solar PV systems. This collaboration, and the learnings from future plant operation, could
serve as a model for future medium-scale projects connecting into the distribution network.
Background
UQ is constructing a 3.3 MW PV pilot research array with funding from the Education Investment
Fund at its Gatton campus west of Brisbane. UQ proposed to connect this array using one of the
existing 11 kV supply connections at the southern edge of the campus. Energex expressed concerns
that such a connection could present challenges to other customers on this 11kV feeder and other
customers supplied by Gatton zone substation generally. Energex expressed a preference for the
solar plant to be connected at 33 kV. However, a 33kV connection was expected to cost significantly
more, requiring costly transformers and ancillary infrastructure.
Process undertaken
UQ commissioned a feasibility study to address the technical concerns raised by Energex. The
technical concerns generally centred around the potential for impacts to the network under
conditions in which the solar plant output dropped suddenly (e.g. due to a passing cloud).
The feasibility study reviewed the impacts of various plant operation scenarios on transient voltage
regulation, steady state voltage regulation, power factor, distribution line losses, harmonic
distortions, and voltage flicker. The study found that the proposed PV system will have a small and
manageable impact on the Energex 11 kV network. Furthermore, the potential for battery storage
units, to be included as part of the overall EIF Gatton project, could provide further network
performance improvements.
1 University of Queensland Gatton 3.3 MW Photovoltaic Array

Knowledge Sharing Report
Engineering Design and Procurement – Nyngan Solar Plant

Project Name: AGL Energy Solar Project (Nyngan Solar Plant)
Knowledge Category: Technical

Knowledge Type: Technology 3C
KEY LEARNING
The construction of a utility scale solar project involves taking standard designs and localising them
to the local standards and codes, as well to local site requirements. This involves co-ordinating
international design teams with local subject matter experts to provide code compliant designs for
cost-effective procurement and implementation.
IMPLICATIONS FOR FUTURE PROJECTS
Future projects will benefit from the localisation of system designs and components to local
standards and codes. This will enable future projects to be more easily replicated in similar
conditions, without restricting the ability to implement improvements and new innovations into
designs.
It is important however that project planning and cost estimates factor in the requirement for site-
specific design localisation, as well as localisation of new and innovative designs, components and
methods.
Site-specific design examples include:
• Local environmental conditions – even if local standards are met, Australian conditions vary
widely across the continent, including insolation, humidity, maximum temperature, wind
conditions and the seasonality of all these parameters;
• Local transport requirements – road access and distance from ports and industrial centres
may impact engineering design, procurement, logistics, and project implementation; and
• Local site conditions – including vegetation, soil conditions, site hydrology, etc may also
require local nuances to standardised designs.
The availability and experience of local and regional engineering and construction firms can aid in
understanding local conditions and requirements. This, coupled with international expertise and
subject matter experts, can provide suitable and practical designs for local site conditions.
KNOWLEDGE GAP
Finding suitable expertise and standards for this scale of solar power project in the Australian
context can be challenging. Australian expertise exists for large scale power and infrastructure
projects that can be transferred to the solar energy context, with the assistance of international
experts with experience in implementation of utility scale solar projects. Australian standards exist
for large scale infrastructure projects but aren’t necessarily relevant to large scale solar projects.
International best practice can be helpful to level set standards requirements and expectations for
utility scale solar plant.
BACKGROUND
Objectives or Project Requirements
The Nyngan Solar Plant project needs to meet local code requirements, and must be delivered in a
cost-effective manner to meet AGL Energy’s project requirements.
In addition, AGL and First Solar will seek to optimise project delivery methodologies to ensure that
future projects can be more easily implemented, taking into account lessons learned during delivery
of the Nyngan and Broken Hill solar projects, and allowing for incorporation of future design and
delivery improvements.
Process undertaken:
First Solar underwent a thorough evaluation of local expertise, in terms of consulting engineering
firms and value-add suppliers and contractors with which to form long-term relationships, via a
competitive tendering process. Local firms were engaged and enabled in terms of First Solar
practices and innovations, and also provided local expertise to ensure First Solar’s awareness and
understanding of local nuances were incorporated into designs. This approach ensures First Solar
can provide a suitable mix of international innovation and local expertise to deliver the project.
First Solar has also leveraged its experience on overseas projects to build local knowledge about
solar design and construction methods. First Solar has created an in-house project engineering team
which works with local consultants to understand Australian standards and design conditions. In
addition, representatives from AGL Energy visited the United States and held design workshops with
the First Solar engineering team and discuss AGL’s specific requirements for the projects.
First Solar has also worked closely with the local manufacturing industry to build knowledge and
capacity for delivery of plant components. In particular, First Solar has collaborated with IXL to
develop the design and supply for the structural components for the solar plants. This collaboration
has involved many factory visits and workshops which help to share knowledge between the solar
industry and the manufacturing industry.
International Knowledge Transfer – Nyngan 4D
Solar Plant
Knowledge type: Construction
Key learning
Australia has minimal experience in the delivery of utility scale solar projects and has the potential to
benefit greatly from knowledge transfer from more developed international markets, particularly
Europe and North America.

As the amount of local utility scale solar experience grows within Australia, it is expected that less
and less international knowledge will be required. Future projects, including Broken Hill, will be able
to leverage more local experience (i.e. Nyngan) and the international influence will be more limited
to advances in technology and highly technical areas (i.e. control systems, commissioning).
Knowledge gap
Several areas were identified as reliant on international capabilities:
 Module, inverter and component supply,

 Construction management – means and methods,
 Commissioning, and
 Operations and Maintenance.
Background
Process undertaken
 As a part of the subcontractor education and bidding process for the Broken Hill project,
over ten different local and regional contractors visited the Nyngan site accompanies by First
Solar employees. These site visits provided contractors with the opportunity to better
understand, quantify and price the work involved in solar project delivery and build up the
knowledge and competency of the bidders.
 After First Solar identified a gap in the understanding and willingness of contractors to
perform waste recycling services at the Nyngan site, First Solar decided to perform the
service directly. For the Broken Hill project, contractors were able to come and understand
the recycling process and subsequently incorporate the work into bid packages for the
Broken Hill project. This represents two important features of knowledge sharing: 1) The
transfer of skills from international players (First Solar) to local contractors,; and 2) The
growth in jobs and capability within local industry.
 Several highly qualified members of First Solar’s SCADA and Commissioning teams visited
the Broken Hill and Nyngan sites, preparing for the upcoming work and training local staff.
 The First Solar O&M team have hired three new local employees, with two of them spending
several weeks training in the USA, splitting time between project sites and the First Solar
Network Operations Centre in Tempe, Arizona.
 First Solar has sent a number of commissioning specialists from their USA base to Nyngan to
assist with technical knowledge and leadership during the preparation for commissioning
the first block of the Nyngan project.
 First Solar has rotated a number of experience construction managers to share means and
methods related to the sequencing of construction activities and the optimisation of
installation activities.
Preparation of connection studies 2E
Key learning
The preparation of technical modelling and connection studies to support a Connection Agreement
with a Network Service Provider (NSP) is complex and time consuming.

It is important to allow sufficient time in the project schedule and budget in the project financial
model to accommodate preparation of connection studies. The preparation of these studies is an
iterative process and studies may need to be revised as the project design evolves. The status of the
grid network, including changes in local demand growth and/or transmission line and substation
construction projects, may also need to be taken into account.
Knowledge gap
It may be useful to provide a “how to” guide for preparation of grid connection studies and technical
modelling. A technical seminar or short course may also be appropriate. The course could bring
together developers and NSPs to discuss the requirements of the National Electricity Rules with
respect to connection studies and to review specific NSP requirements for generation projects.
Background
The grid connection process begins with a Connection Enquiry submitted to the NSP. The NSP may
then request specific connection studies and technical modelling, which define the Generator
Performance Standards (GPS) for the proposed generation facility. The GPS will form the technical
basis of the Connection Agreement between the NSP and the project proponent.
Process undertaken
AGL submitted initial Connection Enquiries for the Broken Hill and Nyngan projects in January 2010,
and then prepared technical studies to define the performance of the initially proposed projects.
However, as the projects evolved, the capacity and configuration of the solar plants changed, and
the initial connection studies became redundant. Similarly, the architecture of the grid and forecasts
of load and generation growth changed over time, and these NSPs and the Australian Energy Market
Operator were interested to capture these changes in the grid connection studies. As such, the
preparation of connection studies for the project was an iterative process, which had implications
for project schedule and budget.

5(E) – AEMO Generator Registration

Project Name: AGL Energy Solar Project (Nyngan and Broken Hill Solar Plants)

Knowledge Type: Construction
AEMO Registration

KEY LEARNING
The inverter is the generating unit for a solar PV plant, however bidding Nyngan’s 154 inverters into
the market is impractical. Hence Nyngan is registered as a cluster of generating units with AEMO
(Australian Energy Market Operator) such that market bidding is for one generator and not 154.

Broken Hill was similar, with two parallel blocks of 40 inverters, combined into a single generator.

Inverters are capable of being operated in a number of control modes (voltage control, power factor
control, and reactive power control) allowing them to provide grid support during operation. It is
also possible to provide continuous reactive support, i.e. whilst not generating through the night as
an example, which could be provided as a service to AEMO. There is additional cost for this facility
and to minimise this cost it would need to be included as a technical requirement in the initial
project scope.

The NER (National Electricity Rules) has evolved from an environment where generation was added
to the grid through large, unique, and infrequent projects, e.g. large scale coal fired and gas‐peaker
plants mainly rotating machinery). The NER continues to respond to changes in the industry.
Nyngan and Broken Hill registrations were based on Version 59 of the Rules; by the end of the
project – two years later – the NER was in Version 75. Following the changes in the NER can be time
consuming when there are multiple, smaller, generators based on a common template being
installed.

In some instances the performance criteria in the NER assumes that generation is based on rotating
machinery, which does not apply to solar PV.

Education was a key issue:
 The proponent – AGL, as the Principal, and Jacobs, the Owner’s Engineer – having understood
the inverter technology from wind farms, were able to draw on their previous experience in
wind farm developments by thinking of the modules, inverters and associated transformers as
analogous to a wind turbine with an inverter stage.
 The DNSP (Distribution Network Services Provider) and AEMO – educating technical assessors in
inverter technology, solar energy and the implications for grid security and potential for
reactive support.
 Supplier – typically foreign suppliers have little understanding of the regulatory framework and
the performance inputs and information required from them. For both Nyngan and Broken Hill,
First Solar (USA), the power station EPC contractor, purchased the inverters from SMA (USA),
but technical inputs needed to be obtained from SMA in Germany. Performance data from
these suppliers needed to be checked as, for example, power modelling originally provided by
SMA was for 60hz systems not 50hz Australian networks.
 Contractor – although experienced in solar plant developments worldwide, Nyngan was First
Solar’s first large scale utility development in the NEM in Australia and was unfamiliar with the
regulatory framework.

Discuss the potential to provide reactive services with AEMO at an early stage so that the option to
provide continuous reactive support to the grid can be assessed in the context of the return on
investment of the project and if beneficial then it could be included in the original project scope.

Allow time and effort to educate stakeholders, because between projects there will be changes in:
 The supplier and model of inverter.
 The Rules – as the NER Version changes or projects are implemented in different jurisdictions.
 NSPs – even within the NEM there are numerous NSPs.
 Personnel – normal turnover within stakeholder organisation between or during projects mean
that previous education efforts are lost.

While the time associated with the education of stakeholders would decline with time, ARENA could
accelerate the process of knowledge dissemination by:
 Documenting and making publically available lessons learned from all projects receiving funding
 Hosting knowledge‐sharing workshops aimed at:
o Understanding inverter technology and the implications for providing ancillary services
o Streamlining the Rules for solid state generation

KNOWLEDGE GAP
Solar developments outside of the NEM would be subject to a different regulatory framework.
Knowledge and experienced gained by AEMO in the technical administration of utility‐scale solar
developments would be limited to the NEM until diffused through active knowledge sharing
activities or the movement of individuals into like organisations in other jurisdictions.

There is potential to improve efficiency by amending the Rules so that renewables projects – which
lend themselves to being based on template plants – can be developed and implemented within a
consistent regulatory framework.

Similarly, the NER should be reviewed so that solid state technologies (Solar PV) can be
accommodated alongside rotating machinery‐based technologies.

BACKGROUND
The Australian Electricity Market Operator (AEMO) administers the National Electricity Market
(NEM) within the regulatory framework provided by the National Electricity Rules.

AEMO registration is required in order to be able to input electricity from a generating asset into the
NEM. The registration process considers technical, principally through the Generator Performance
Standards (GPS), and commercial aspects, principally through a review of demand for the electricity
generated – typically demonstrated though a Power Purchase Agreement (PPA).

Process undertaken:
Registration typically follows the following process:
 Site determination – undertaken by the project proponent
 Preparation and submission of a connection enquiry – a request to connect to the NSP
 Response to connection enquiry – the NSP will respond with conditions, including a list of non‐
contestable (must be undertaken by NSP) and contestable works required prior to connection.
The cost of these works will usually be borne by the project proponent. At Nyngan these
included the Essential Energy switchyard, extension to the existing 132kV overhead line and
provision of a Static VAR (Variable Resistance) Compensator at Nyngan substation. At Broken
Hill a potable water line and existing 22kV line needed to be diverted around the solar plant.
 Technical studies are undertaken by the project proponent to establish the GPS.
 Submission of the GPS to the NSP and AEMO for their acceptance, which usually follows a series
of reviews.
 Preparation and submission of registration documentation – this can happen in parallel to the
GPS as the GPS only has to be finalised by the time registration is approved.
 Registration also involves a series of reviews and is usually granted following the monthly
meeting of the AEMO panel, but this can be expedited.

SUPPORTING INFORMATION
 Refer to the companion document to this one on Generator Performance Standards
 AEMO Registration – Information on Network Connections:
http://www.aemo.com.au/Electricity/Network‐Connections
 AEMO Registration – How to Register:
http://www.aemo.com.au/About‐the‐Industry/Registration/How‐to‐Register/Application‐
Forms‐and‐Supporting‐Documentation/NEM‐Generator

5(F) – Grid connection – energisation


Grid Connection

KEY LEARNINGS
First Solar has found no special requirements for the grid connection of the PV Plant outside of what
is normally expected for a new generator. The PV modules essentially behave as DC power supplies.
They are connected to the inverters, step up transformers, collector system and then switchgear.
From the inverters onwards, there is little difference between the solar plant and other types of
inverter output generators, e.g. wind turbines.

The design and implementation of protection settings and the SCADA system needed to be
coordinated between multiple vendors (inverters and relays in particular). Often this will be done
overseas before the equipment arrives in Australia for installation.

As part of AEMO registration and negotiation of the GPS, there was an extended period of discussion
with AEMO and the Network Service Provider (NSP), as they familiarised themselves with the
inverter technology and the impact of solid state generation on network stability. During this time,
the parameters of the inverters changed significantly. A coordinated effort was required to ensure
that any changes to the inverter parameters due to performance requirements was captured and
programmed into the inverters prior to commissioning.

At the Nyngan Solar Plant Essential Energy’s (NSP) concerns over a white powder found on the
surface of some aerial conductors had the potential to delay the commissioning of the 132 KV
connection assets. This conductor was procured by the contractor from an Essential Energy
approved supplier. Following lengthy discussions, a compromise was reached whereby the
commissioning took place on time, but the conductors were required to undergo a thorough testing
regime.

At the Broken Hill Solar Plant the design for the rail crossing of the dual circuit 22kV overhead line
went through the rail operator’s (Australian Rail Track Corporation) rigorous review process. In
order to expedite the approval of the design it was necessary to accept conservative standards
(1/1000 year wind loading) – compare the attached photographs of final Broken Hill 22kV
installation and the 132kV installation at Nyngan.

 To ensure a smooth transition from installation to the grid connection, it would be beneficial for
the EPC contractor to appoint a dedicated protection system coordinator to interface between
AEMO, the NSP, and the protection equipment manufacturers/ suppliers.
 Poor co‐ordination of inverter performance will slow the commissioning process and create
delays in energisation.
 Quality assurance of materials from the factory to site, and storage on site needs to be
managed to ensure materials procured are of the right standard and are not damaged or
degraded prior to installation.
 Start early, allow time, and assign personnel to manage engagement with stakeholders that
provide approvals; delays can adversely impact the overall project.
KNOWLEDGE GAP
There is no real knowledge gap concerning grid connection. However, managing the requirements
of all the stakeholders is a critical aspect that requires attention and should not be underestimated.

SUPPORTING PHOTOGRAPHS

Photo: New 132 kV line at Nyngan

Photo: New 22kV lines crossing over the railway at Broken Hill

5(G) – Generator Performance Standards


Generator Performance Standards

KEY LEARNING
Development and approval of the Generator Performance Standards (GPS) took about 12 months
after the first submission to the Network Service Provide (NSP). This process was about 6 months
longer than what one would expect where the technology is well understood. Additional direct
costs for the Proponent’s team, i.e. ignoring lost opportunity and Contractor costs, would have been
of the order of $250,000 for each site.

The power plant controller (PPC) is the controlling unit for a solar PV plant and together with the
inverters form an integrated system for controlling the operations of the generator. Details of both
elements are critical before the Technical Assessment (Connection) Study can be undertaken to
determine the GPS. Any change in the PPC, inverter equipment or revision to the PPC or inverter
modelling may impact the Connection Study and GPS.

The Proponent (AGL) is contractually responsible for the provision of the study and ultimate
development of the GPS, but First Solar determined the PPC, inverter supplier, model and associated
characteristics which were then used in the GPS. When First Solar changed inverters a significant
amount of time and effort to amend the GPS was required. Technical matters raised by the Owner’s
Engineer would go via the Contractor to the supplier (via the USA to Germany) – and responses
would follow the same trail back to the Proponent. This was not a very efficient way of obtaining
data from SMA, the Original Equipment Manufacturer (OEM).

The technical aspects of registration are covered in part by the GPS, which is subject to review and
approval by both the Australian Energy Market Operator (AEMO) and the NSP. The NSP acts as both
an agent of AEMO and also has a mandate to ensure grid security. At Nyngan, initial technical
studies assumed power factor control mode based on the NSP’s response to the connection enquiry.
Later, during the review of the GPS, AEMO and the NSP were keen to explore the consequences for
the solar plant to provide dynamic grid support. This expanded the scope of technical studies
required to support the GPS and extended the registration process.

Similarly, at Broken Hill the process took longer than would have been expected as the technical
personnel in the NSP took time to investigate in detail the inverter technology and the implications
for their network.

Consider including responsibility for the final technical studies and GPS within the scope of the EPC
contract. This would eliminate an unnecessary interface between those preparing the GPS and the
supplier. It would also align control and impact of changes to the inverters with the responsible
Contractor.

Ensure that the PPC and inverter model is robust in design and proved as early as possible in the
project to avoid delays in approval of the GPS and thus potential delays in registration and
generation.

Include AEMO early in the development of the GPS to gain consensus between AEMO and the NSP
on the inputs into the GPS.

KNOWLEDGE GAP
A general understanding of solar technology will in time diffuse through the local industry.
However, given the range of applications, suppliers and evolution of inverter technology there is no
avoiding the need to become familiar with the specific inverter technology being applied and
facilitating the education of other stakeholders.

There is potential to streamline registration by making a single entity responsible for the
management of the review and approval of the GPS rather than the current requirement under the
NER to submit the GPS for review to both AEMO and the NSP.

BACKGROUND
The Australian Electricity Market Operator (AEMO) administers the National Electricity Market
(NEM) within the regulatory framework provided by the National Electricity Rules (NER).

Part of the NER requirements is the technical assessment of the generator for connection to the grid.
The Network Services Provider (NSP) is responsible for grid security, and also acts as an agent for the
market operator. For a Proponent to connect a generator to a specific point on the grid, the
Proponent, AEMO and the NSP need to agree on what level of performance the generator needs to
attain. This is contained in the GPS. The GPS is determined by a series of technical studies (both
dynamic and static) that describe the performance of the generator while it is connected to the grid.
These studies also show how the grid responds to the generator’s operation.

The GPS also provides the technical input into the AEMO registration process – see the companion
report on AEMO registration. Consequently, AEMO and the NSP need to agree to the GPS.

Process undertaken:
Development and approval of the GPS typically follows the following process:
 Collection of inputs, including:
o Establishing the NER version and studies required – from AEMO.
o Site‐specific physical data – from site determination.
o Connection and grid conditions – from the NSP’s response to the connection enquiry.
o Inverter performance data and modelling objects – from the supplier.
o Network models – from the network operator (AEMO).
 Modelling and other technical studies to determine the performance levels that will go into the
GPS.
 Development and submission of GPS in the prescribed format to both the NSP and AEMO for
their review.
 Acceptance of the GPS by the NSP and AEMO, which usually follows a series of reviews.

 Refer to the companion document to this one on AEMO registration.
 AER Generator performance standards information booklet
https://www.aer.gov.au/node/21331
 AEMO Generator Performance Standards
http://www.aemo.com.au/Electricity/Market‐Operations/Generator‐Performance‐Standards
Definition of project scope between multiple
contractors 2D
Knowledge type: Logistical
Key learning
AGL engaged separate engineering, procurement and construction (EPC) contractors to deliver the solar plant and
the grid connection assets at each project site. While not uncommon, splitting the scopes in this introduces technical
and scheduling interfaces, which add to risks during project delivery.

For future projects, it may be advantageous to engage a single EPC contractor to deliver the scope of work.
However, this approach would need to be balanced against the complexity and cost of the project.
Knowledge gap
The delivery of large-scale solar projects requires specialised engineering design and construction skills and the
market for these services is relatively limited in Australia. Similarly, the delivery of grid connection assets in Australia
(substations and transmission lines), requires specialist expertise and experience. It may be difficult for a single
contractor to offer both of these services. However, as the market for large-scale solar generation in Australia
matures, the number of contractors able to offer these services will likely expand.
Background
AGL engaged an EPC contractor to design and construct the solar plants at Nyngan and Broken Hill. AGL engaged a
second EPC contractor to design and construct the grid connection assets for each project. At Nyngan, the
connection scope of works includes installation of a new substation and switchyard at the project site and a new
section of 132kV line to connect into the existing Nyngan – Cobar 132kV line. At Broken Hill, the connection scope of
works includes construction of a new 22kV line to connect into the existing TransGrid substation.
Process undertaken
The advantage of splitting the overall scope of work into the solar plant assets and the connection assets was that it
allowed AGL to engage specialist contractors who could best perform their respective scopes, at the lowest overall
cost. However, the disadvantage of this approach is that it introduces technical interface and scheduling risks
between the contractors. Furthermore, there may be site access and work health and safety issues with two
contractors working on the same site. These issues potentially create commercial risks for the site owner. In
addition, the legal and technical consulting costs of negotiating separate EPC contracts are likely to be more
significant than negotiating a single contract.
Local Procurement – Nyngan Solar Plant


Knowledge Type: Supply Chain 3A
KEY LEARNING
The delivery of a utility scale solar project requires supply of equipment and materials from
numerous specialty and commodity suppliers. The establishment of an in-country supply chain was
deemed the most effective way to support project delivery at the scale of the Nyngan Solar Plant
project.
Having an established in-country supply chain will assist in the planning of future projects in three
areas: (1) scheduling (2) cost estimates and (3) quality.
Development of an in-country supply chain will assist project developers and engineering,
procurement and construction (EPC) contractors to better understand lead times for order and
delivery of materials and equipment to a project site. This will ensure that project schedules
accurately reflect expected delivery times, which reduces project execution risk. Furthermore, the
development of relationships between project developers, EPC contractors, and supply chain
providers will likely reduce delivery lead times and improve suppliers’ response times and flexibility
when design or schedules changes arise.
As the supply chain develops in Australia, and suppliers better understand the requirements of
developers and contractors, the cost estimates for equipment and materials will become more
precise. Where suppliers have been used on previous projects, economies of scale may develop as
suppliers are able to invest in new capital or processes that drive down unit prices.
Quality control processes can be more tightly managed with a local supply chain. Local standards are
better understood and quality control audits are more easily done.
KNOWLEDGE GAP
Prior to the Nyngan and Broken Hill projects, there was no significant supply chain for utility scale
solar in Australia. It is crucial for Australia to develop and maintain the local procurement knowledge
base required to supply the commodities required to deliver solar projects. With the ever increasing
pressure of low-cost global competition, the establishment and encouragement of local
procurement will safeguard Australian industry and job creation.
BACKGROUND
The Nyngan Solar Plant project requires the local procurement of cables, transformers, power
conversion equipment, switch gears, mounting structures and other miscellaneous equipment.
These commodities will be sourced through a number of suppliers within Australia, including
suppliers who are new to supporting the solar industry.
Process undertaken:
First Solar underwent a thorough evaluation of the availability of local procurement suppliers. First
Solar collaborated with industry bodies such as the Industry Capability Network (ICN) to locate
contractors and suppliers within the project regions, as well as across multiple Australian states.
RFIs and RFPs were issued to gain additional information related to supplier interest and capability.
Potential suppliers’ responses were reviewed by cross-functional teams and then shortlisted. Subject
matter experts confirmed that the scale and technical requirements of the project could be met.
Final determinations were made based upon cost competitiveness and level of quality. Supplier
mentoring has been put in place for those companies who have transitioned from supporting other
industries to now supply the solar industry.
IXL Manufacturing Launch May 2014

ATTACHMENTS
• Press Release: IXL Group Opens Structure Manufacturing Plant in Adelaide to Supply First
Solar Australian Projects
• Industry Development and Job Creation in Australia

Labour and Accommodation – Nyngan Solar Plant


Knowledge Category: Logistical
Knowledge Type: Human Resources 3B

KEY LEARNING

The construction of utility scale solar project involves a significant amount of skilled and unskilled
labour. Site locations in regional areas such as Nyngan are not always able to meet the full labour
requirements and non-local labour must be sourced to add to the local workforce.


It is important that project planning and cost estimates factor in the availability of skilled and
unskilled workers within the project area. If the project will require specialised trades in addition to
those that can be sourced within the local area, then consideration must be given to the following
issues:
- An estimate of the quantity and duration of non-local workers required for the project;
- A search for the most suitable source of non-local workers and the likely mode of transport
to the project area;
- A thorough investigation of the local accommodation alternatives, including hotels, motels,
caravan parks and residential dwellings; and
- Evaluation and costing of new or temporary accommodation to host the non-local workers.
Whilst the cost of labour in regional and remote towns is similar to those in the capital cities, where
additional labour from outside the project region is required, it will be necessary to provide local
accommodation and mess services which will increase project cost. Sourcing non-local labour will
also impact the local community, which must be consulted to optimise the economic benefit while
minimising impacts on community amenity.
To the extent that skills in and knowledge of utility-scale solar become concentrated in a relatively
small fly-in fly-out labour pool rather than more broadly disseminated throughout communities and
regions, this may delay or impair the uptake and acceptance of large-scale solar in Australia.
It is important that local governments play a role in identifying local labour conditions and
community views/preferences on accommodation alternatives. Some communities encourage
temporary accommodation facilities to be established outside the town to minimise disruption,
while others may prefer the facilities to be within the town area so that the economic benefits can
flow directly to local businesses. Local hotel/motel operators also have a range of opinions on long
term tenancies, balancing the security of a long term room booking with the desire to have some
availability to host tourists and travellers. These preferences will be site specific and local
government should be encouraged to represent the views of communities.

KNOWLEDGE GAP

First Solar has provided on-site skills training to site workers to build local solar construction
capacity. In addition, First Solar’s engineering and procurement team has worked with local
fabricators to modify First Solar’s standard global designs to meet local design requirements.
Additionally, a collaboration between IXL, the company involved in producing structural components
for the project, and OMCO, First Solar’s supplier to similar projects in the USA, has provided
knowledge and skills transfer opportunities.
BACKGROUND

The Nyngan project will require a workforce of up to 250 people at peak construction, which will
comprise a mix of functions including project management, engineering, quality, safety, project
controls, supervisors, trades, administration and unskilled labour. The workers will be employed
though a number of companies, including the prime contractors, subcontractors and labour hire
agencies.

Process undertaken:

First Solar underwent a thorough evaluation of the availability of labour, subcontractors and
accommodation providers though numerous visits and a formal subcontractor’s roadshow in 2013.
There were also numerous advertisements posted in local news sources and direct engagement at
the Nyngan Agricultural Show and the AGL Community Consultation event. A competitive tender
process was held for the constructions of temporary accommodation facilities and for the major
subcontracting packages.


Figure 1 - Nyngan Camp Open Day
Figure 2 - Nyngan Ag Show

Figure 3 – First Solar Subcontractor Forum Promotional Flier

Material Delivery – Nyngan Solar Plant 4C

Knowledge category: Logistical
Key learning
Opportunities for cost reduction exist in the optimisation of material delivery – specifically through
the evaluation of multiple delivery points (Adelaide vs. Sydney) and form of transport (road vs. rail).
It is also important to monitor the existing transport networks to maximise regional transport hubs.

Following the experience in Nyngan, First Solar has established and built on existing relationships
with transportation and logistics companies. Significantly, Adelaide has been identified as the
optimal Port for module shipment for the Nyngan project.
Knowledge gap
Early deliveries to site were handicapped by delays to the completion of the elevated access road
and the deceleration lane on the main highway. Transport and logistics costs in Australia are
noticeably higher than in global market – estimated to be 30-50% higher than in the USA.
Background
Process undertaken
Material delivery for the Nyngan project has involved the following work items:
 Module delivery by rail and road from Port Adelaide,

 Table delivery by rail and road from Sailsbury South (SA),
 Rail deliveries to Warren and truck transport to Nyngan,
 Power Conversion Station (PCS) delivered from Newcastle,
 Photovoltaic Combining Switchgear (PVCS) and Photovoltaic Interconnection Switchgear
(PVIS) delivered to Nyngan from Adelaide, and
 Multiple other components delivered from global and regional locations.
Photo: Module Delivery
Photo: Module Delivery
Photo: PVCS Delivery
Photo: PVIS Delivery
Local supply chain responsiveness,
limitations and areas for improvement –
Nyngan Solar Plant 4E
Key learning
 Local supply chain is non-existent for standard products in foreign markets (e.g. I-Beam
posts used in the USA could not be sourced in Australia)
 For imported products, foreign suppliers are often unfamiliar with Australia Standards and
sometimes with export requirements
 Imported products increase lead time and shipping costs
 Local suppliers unfamiliar with the technical requirements of Utility scale Solar Farms
 Local suppliers have a higher expectation of specification level than US suppliers i.e. the
Australian expectation is a fully engineered design specifications not a performance
specification. This results in more time and resources being dedicated early on in the
project.

 Work directly with Original Equipment Manufacturers (OEM’s) for critical equipment i.e.
Photovoltaic Combining Switchgear (PVCS)
 Develop clearly defined and documented Scope of Works (SOW) and Divisions of
Responsibilities (DOR)
Knowledge gap
The primary knowledge gap for supply chain in the Australian solar industry is the historic absence of
a utility scale solar supply chain in Australia. This can be best summarised as follows:
 Absence of local manufacturing of key components – PV modules, inverters.

 Absence of local manufacturing of enabling components – mounting structures,
inverter/transformer integration, combined boxes, cables.
First Solar has worked primarily on localising the majority of the enabling works, much of which is
detailed in the attached brochure.
Background
See industry capability brochure attached.
 First Solar has organised 2-way knowledge sharing sessions between US suppliers and local
suppliers i.e. IXL/OMCO, Ampcontrol/Fibrebond
 Continue to work with local suppliers to drive process efficiencies and cost reduction
opportunities
Photo: Table assembly
Photo: Table Assembly
Photo: Shipment of tables
Photo: Adelaide to Nyngan route for module/table shipment
Switchyard construction – Nyngan Solar Plant 4F

Key learning
The construction of electrical infrastructure (e.g. substations, switchyards, or overhead lines) assets
needs to consider the specific requirements of the Network Service Provider (NSP) as the ultimate
owner of these assets. Essential Energy is the NSP for the Nyngan Solar Plant.
Power distribution and transmission infrastructure varies across regional Australia, so the impact of
connecting a solar plant will have a unique impact on the performance of the local electricity grid.
Not every solar plant will require a switchyard, but many may require some other form of local
augmentation, and most will require an overhead line.
Unlike other assets constructed at the solar plant, the electrical infrastructure required by the NSP to
connect to the solar plant and reinforce the grid, specifically as a consequence of the generator
connecting to the grid, are Contestable Works, meaning that either the NSP may construct and
operate the asset or that they are built by the generator and gifted to the NSP. This will also include
the provision of leases for any associated land. The governance of this is contained within the
National Electricity Rules (NER) and associated Regulations.

Key learnings from the construction of the electrical infrastructure – Essential Energy’s assets – for
the Nyngan Solar Plant that could be used on future projects:
 Scope of construction – The solar plant owner is expected to take responsibility for augmenting
the grid so that the solar plant can be connected while only affecting the performance of the
grid as per the NER. The NSP, with responsibility for the performance of the grid, will expect to
direct the scope of the additional assets, which would ultimately be their assets. The whole life
cost of these assets must be considered as part of the feasibility study for the project.
 NSP requirements – The additional electrical assets will need to comply with the NSP’s:
o Technical requirements –the electrical design will need to comply with the NSPs internal
standards and specifications. The designer and construction contractor will need to have a
working understanding of these and also allow for all the processes required to gain
approval from the NSP. Prior experience by the contractor with the NSP is essential.
o Procurement policies and standards – some NSPs have approved suppliers, materials and
equipment so the construction contractor should consider the cost and timing implications
of procurement processes unfamiliar to them.
o Construction procedures and processes – the NSP may want to impose design approvals or
hold points on the construction or undertake their own parallel Quality Assurance
processes. The construction contractor should consider the cost and timing implications of
the NSPs involvement as a key stakeholder in the design and construction of the assets.
 Agreement – the NSP’s requirements for the additional assets need to be clearly defined and
agreed between the solar plant owner and the NSP the basis being the NSW Department of
Resources and Energy’s “Service and Installation Rules” as modified by the NSPs specific
requirements. The agreement(s) between the owner and the designer and constructor of the
grid augmentation works must be aligned with the NSP’s requirements, and the designer and
constructor must be accredited by the NSP to undertake the work.
 Construction – the ideal location for a solar plant is usually on an area of flat land. If the area is
prone to flooding or inundation then specific attention to hydrological and drainage issues will
be needed. At Nyngan the NSP switchyard and AGL substation were constructed on a bench to
ensure that these assets were elevated above the surrounding land and water would drain
away.
Knowledge gap
There is no real knowledge gap concerning the construction of assets such as switchyards and
substations or installation of electrical infrastructure to augment the grid. However, satisfying the
NSP’s requirements is a critical aspect in delivering a solar project and needs to be managed to avoid
delay in connecting the solar plant to the grid.
Background
The Nyngan Solar Plant is connected to the grid via the connection works that included the new
132kV switchyard and approximately 3km of 132kV transmission line. In addition to the switchyard
and transmission line, AGL also gifted new reactive plant at the Nyngan 132kV substation to
Essential Energy.
Process undertaken
The process for connecting embedded generation is governed by the NSW Department of Resources
and Energy’s Service and Installation Rules as augmented by the NSP requirements.
AGL applied to Essential Energy for a high voltage connection as a potential large embedded
generator. This preliminary connection enquiry initiated a process that culminated in Essential
Energy preparing the design requirements for the connection and committing to the connection
subject to the design criteria being met.
AGL engaged an ASP3, an Essential Energy accredited designer, to prepare and eventually construct
the design under an EPC contract (the contractor is also ASP1 accredited for construction).
Following approval of the design by the NSP, and other compliance with the development consent
conditions, construction of the assets commenced. Essential Energy was actively involved in
monitoring the construction of the assets and carrying out its own quality assurance processes and
inspections.
 NSW Department of Resources and Energy – Service and Installation Rules
http://www.resourcesandenergy.nsw.gov.au/energy-supply-industry/pipelines-electricity-gas-
networks/network-connections
 Essential Energy – HV connections and large embedded generators (CEOP8079)
http://www.essentialenergy.com.au/asset/cms/pdf/contestableWorks/CEOP8079.pdf
 Essential Energy – Connecting to the network information pack
http://www.essentialenergy.com.au/asset/cms/pdf/Reg/CTNIP_FINALv1.pdf
Transmission easement process – Nyngan 4G
Solar Plant
Key learning
Construction of a utility scale solar project in regional Australia will typically require the construction
of a transmission line in order to connect the solar plant to the grid. Construction and operation of
the transmission line will require the creation of an easement in order to provide a registered legal
right that applies over the land. This process needs to consider the specific requirements of the
Network Services Provider (NSP) – Essential Energy for the Nyngan Solar Plant and other
landholders.

Key learnings from the process for securing the transmission line easement for the Nyngan Solar
Plant that could be used on future projects:
 NSP requirements – Essential Energy like other NSPs have specific requirements and
processes for formalising easements over a particular parcel of land in their favour. It is
important that these requirements are captured in the agreement with landholder in order
to avoid any delays in design approval and construction.
 State road – Road and Maritime Services (RMS) are responsible for state roads, such as the
Barrier Highway, however, they typically do not have a title which prevents the registration
of an easement. For Nyngan, the Bogan Shire Council is the controlling authority from
whom we needed to seek a letter of consent.
 Rail crossing – Country Regional Network is the authority for the rail crossing required for
the transmission line easement. They have specific requirements and a formal corridor
access application process which is managed on their behalf by John Holland.
 Crown lands – Crown Lands within NSW Trade & Investment help with progressing
easement creation requests over Crown land to ensure that environmental and cultural
heritage aspects are appropriately addressed.
The creation and registration of an easement for the transmission line is a very specific process that
will require the assistance of a knowledgeable surveyor and specialist legal advisor to ensure that it
is navigated in a manner that does not delay design approval and construction.
Knowledge gap
There is no real knowledge gap concerning the creation of transmission line easements that are
required for utility scale generation projects. However, it is a critical aspect in delivering a solar
project and needs to be managed to avoid delay in connecting the solar plant to the grid. Creation
of an easement is based on state requirements which are relatively well understood by those
familiar with the easement creation process.
Background
The Nyngan Solar Plant is connected to the grid via the connection works that included the new
132kV switchyard and approximately 3km of 132kV transmission line. The 132kV transmission line
connects to the existing Nyngan – Cobar transmission line and required the creation of an easement
in the favour of Essential Energy.
Process undertaken
Prior to creation of an easement AGL established option agreements with the relevant landholders
to ensure that legal arrangements were in place as part of the project development. AGL engaged a
specialist legal advisor in order to understand the framework and process for creating the easement
for the 132kV transmission line. This included an early identification of any potential environmental
and/or cultural heritage matters.
A local surveyor was used with previous experience in easement creation to ensure that survey plans
were consistent with Land and Property Information NSW (LPI) requirements. The surveyor also
pegged the easement for the contractor completing the construction works.
The easement documentation and plans were submitted to LPI through the legal advisor to ensure
that information was submitted to LPI in the correct sequence to help the way through the
registration process.
AGL liaised with Crown Lands in order to progress the section of transmission line with covers the
crown land – a former stock route and engaged Essential Energy to complete the process of
registration for this component given their statutory powers.
 Essential Energy – Creation of Easement: For Services (CEOF6496)
o https://www.essentialenergy.com.au/asset/cms/pdf/contestableWorks/CEFD6496.pdf
 Essential Energy – Creation of Easement: Landowner Deed (CEOF6274c)
o https://www.essentialenergy.com.au/asset/cms/pdf/contestableWorks/CEOF6274c.pdf
 Essential Energy – Design Information Transmission HV Connection Works: Section 3.7
includes transmission line easement requirements.
o http://www.essentialenergy.com.au/asset/cms/pdf/hv/GenericHVDesignRequirements
HVRequirements.pdf
 Crown Lands – Lease and licences: http://www.lpma.nsw.gov.au/crown_lands/leases
Early Works Activities – Nyngan Solar Plant 3D
Key learning
A number of early works activities were required to enable site mobilisation and facilitate the
commencement of construction at the Nyngan Solar Plant site. These activities included upgrades to
the site access turnoff and access road, initial earthworks, and construction of a temporary water
supply for dust suppression. Key lessons learned included:
 Site access – Construction of a solar plant involves a steady number of vehicle movements to
provide delivery of equipment, materials, and labour to the site. It is critical to define the
requirements for upgrade of the site access turnoff, as well as the methodology for
construction of site access roads, taking into account the number and type of vehicles and
seasonal weather patterns.
 Earthworks – The Nyngan project site is extremely flat, and heavy rains which occurred
during grading of the site access road and the substation bench area seriously impacted the
early grading activities, rendering certain areas inaccessible for a period of weeks and
causing delays to the project schedule.
 Water supply – A temporary water supply was required to provide water for dust
suppression during construction. AGL and First Solar explored a number of possible options
for the water supply, but delays to implementing a preferred solution led to adverse cost
outcomes and unnecessary distractions to project execution.

Enabling works are, by definition, critical activities which must occur prior to full-scale project
implementation. For the Nyngan Solar Plant project, an accelerated project schedule compressed
the front end of project delivery which meant that key activities such as upgrades to the site access
and the access road, and construction of a temporary water supply, were not completed prior to site
mobilisation. In addition, a series of heavy rains occurred during implementation of the enabling
activities which necessitated re-work of the access road and caused an approximately two week
delay to full-scale site mobilisation.
Future projects could benefit from identification and resolution of potential issues relating to early
works. Key items which should be considered include:
 Access – Every site will have different access requirements depending on local and state
government requirements, proximity to local residents and businesses, and the number of
vehicle movements. It is important to define the requirements for upgrades to site access,
in particular the intersection with adjacent roads. In addition, it is important to understand
how adverse weather may impact construction of access roads, and to build in contingency
to project schedules to allow for delays due to wet weather.
 Earthworks – Because solar project sites may be quite large and generally flat, the sites may
not be well drained in the event of heavy rains. It may be beneficial to construct access
roads progressively, such that vegetation removal and ground disturbance is minimised over
wide areas and construction is constrained to discrete sections which can be started and
finished before moving on to adjacent areas. It is also important to understand how site
earthworks may impact drainage towards neighbouring properties and adjacent roads.
 Water Supply – Depending on site location and local water availability, it may be difficult
and/or expensive to supply water for dust suppression during project construction. It is
important to consider the various options for supplying/storing water to the site (pipeline,
site dam/tanks, water trucks) and the costs and implications of each option. It is important
to carefully estimate the amount of water which could be required in the event of prolonged
hot and dry conditions, taking into account the area of which construction activities are
being conducted. It is also important to consider community concerns around the use of
water for dust suppression as opposed to irrigation.
Knowledge gap
There is no real knowledge gap concerning enabling works, considering that many of these issues
would be typical to any large-scale construction project. However, experience with construction of
utility-scale solar projects is fairly limited in Australia, and regulators and contractors may not be
aware of how these issues may affect delivery (in terms of cost and schedule) of a solar energy
project. For the Nyngan project, the specification and negotiation of requirements for highway
access upgrades was challenging, based in part on uncertainty around the number and duration of
vehicle movements to the site.
Background
To enable site mobilisation for the contractors engaged to deliver the solar plant and the substation
and transmission line, it was critical for AGL and First Solar to undertake some early activities prior to
full-scale mobilisation. Upgrades to the site access were required by the local Council and NSW
Roads & Maritime Services (RMS) to ensure the safety of traffic flows along the Barrier Highway.
Construction of an access road from the highway to the project site was also critical to enable
vehicle movements to the site, including deliveries of equipment required to construct the
substation and transmission line. In addition, it was essential to identify and implement a preferred
solution for delivery of water for dust suppression during construction.
Process undertaken
AGL engaged a local contractor to construct the rural site access to enable vehicles to safely enter
and exit the site, and to construct a security gate to control access to the project site. Future work
will involve construction of a more developed intersection and turning lane from the Barrier
Highway.
AGL engaged First Solar to construct the site access road from the highway to the project site, and
First Solar in turn engaged an Australian civil contractor to build the road. Construction of the access
road was impacted by heavy rains which prevented movement of vehicles and caused an
approximately two week delay to road construction and, in turn, the overall project schedule. In
addition, due to the very flat topography, the site does not drain well and ponds develop in low
spots which has necessitated additional works to improve drainage in certain areas.
AGL and First Solar investigated a number of options for water supply to the site, including accessing
water from the nearby Cobar Water Pipeline, pumping water from the weir at Nyngan, or trucking
water from the Council depot at Nyngan. Each option had advantages and disadvantages in terms of
cost and infrastructure required, as well as the type of water and the need for acquisition of water
rights. First Solar ultimately arranged to purchase water from a nearby landowner with water rights,
and to install additional pipe required to deliver the water to the site.
Site Mobilisation – Nyngan Solar Plant 4A

Key learning
The majority of the key learnings involved in site mobilisation were driven by identifying and
engaging regional companies to provide the site mobilisation services. A number of capable and
experienced local players were identified in this space, and while none of the companies had solar
project experience the site mobilisation process is fairly consistent with non-solar projects and no
major issues or gaps were identified.

The site mobilisation process has been extremely useful as guidance for the Broken Hill site
mobilisation, which occurred several months later.
Knowledge gap
No meaningful knowledge gaps were identified in this area. Western NSW is well equipped to
support site mobilisation for utility scale solar projects. In more remote areas, constraints are likely
to be found in the areas of connectivity and availability of power/water.
Background
Process undertaken
Site Mobilisation is primarily concerned with establishing a site presence, including the following
activities:
 Installation of site offices, toilets and conference facilities,

 Establishment of lay-down area for material delivery,
 Building site fencing at the entrance, perimeter and surrounding offices/car park/lay-down,
 Connection of site utilities (power, internet) and establishment of water supply/storage, and
 Preliminary site preparation – clearing/cutting grass.
Photo: Early site mobilisation works
Photo: Project building installation
Access Road Construction – Nyngan Solar 4B
Plant
Key learning
Thorough preparation and execution of the access road works is important to ensure timely delivery
of the project. Any delays in delivery (i.e. weather) will impact the project delivery schedule as the
majority of site works occur after the completion of the access road.

There will be limited duplication in this area for the Broken Hill project, with site dynamics different
from a topographic and geotechnical perspective. The Nyngan project experience did lead to a
heightened sense of urgency for access road construction as well as awareness about delay risk
related to weather and CEMP.
Knowledge gap
No knowledge gaps were identified for the access road construction. The capability of local
contractors is consistent with global standards in this area.
Background
Process undertaken
Access road was constructed between the Barrier Highway and the Nyngan Solar Plant. The original
plan was to build the road at the existing ground level, but heavy rain and flat ground made it
necessary to increase the elevation of the road to facilitate site access in the event of heavy rains.
Photo: Original site access road after heavy rain
Photo: Original site access road before heavy rain

5(A) – Civil works


Civil Works

KEY LEARNINGS
The Nyngan Solar Plant site is very flat making drainage difficult due to the minimal fall able to be
achieved. During the execution of the civil works, we experienced above average rainfall which at
times severely impacted the works, schedule and budget. Inclement weather was identified during
the project planning phase of the project, however, the degree of rainfall did have an impact on
logistics, materials deliveries (both local and interstate), transportation, internal site road condition
and development, laydown yard activities, and the opportunity to use heavy tracked equipment,
trenchers, cranes, etc. Rainfall affecting these activities resulted in delays until the saturated ground
was able to dry out through standard dewatering and pumping activities.
Within the project site, civil scope included internal access roads on the perimeter of the site as well
as internal PCS block alleyways, along with car parks, two laydown areas for storage of materials, all
of which required continual maintenance through the timeline of the project. Maintenance
requirements for civil works included grading, leveling, dust abatement, application of dust inhibitor
(Canola oil and Dustex were trialed, but while longer lasting were ultimately less cost effective than
water), and dewatering when localised flooding occurred.
A critical component to the civil works was the establishment of the water download pipe area,
along with the provisioning of remote water provided by pipeline and a dam for reticulation located
just outside the northern boundary of the Nyngan project site.
The Broken Hill site has an undulating landscape sculpted by flash‐flooding. The attached aerial
photograph shows the different aspects of the civil works package: fencing, preparation of
hardstands and laydown areas, establishment of the construction water supply, roads, cut and fill,
and armoring of new and existing drainage channels.
The civil works were completed prior to commencement of structural and electrical activities.
Large infrastructure projects, such as solar plants, which are approximately 250 and 140 hectares
(under arrays) at Nyngan and Broken Hill respectively, depend on reliable access in order to progress
different construction activities.
First Solar had given these issues some thought and through judicious use of local contractor yards,
storage locations, and delayed commencement, was able to manage project risk and maintain
continuity for the most part. Good project management execution can ensure multiple plans are in
place to deal with most events that can be an impediment to project execution.
For example, in order to minimise impacts from inclement weather at Nyngan, which could
otherwise cause material delays, access roads and alleyways needed to be maintained throughout
the construction period – particularly once tables had been installed and there were open trenches
limiting access to a single point for many construction areas.
Finally, the consideration of local site conditions in designing mounting structures to work with the
site topography reduces the civil works cost, as this provides opportunity to minimise the required
cut, fill, levelling, drainage etc. Despite the civil package having the smallest value compared to the
structural and electrical works (less than 10% of the total contract price), civil costs at both Nyngan
and Broken Hill exceeded $10 million, and therefore cost savings can be significant.
 Installation of weather‐proof access roads to be prioritised at the project start in order to
avoid delayed or out of sequence delivery of equipment and materials, and potential for
civils re‐work due to local rains. This lesson was learned at Nyngan and implemented at
Broken Hill.
 Upfront design work on mounting structures and layout to consider the local topography of
the site can result in significant cost savings associated with civil works.
 Develop clearly defined and documented Scope of Works (SOW) and Divisions of
Responsibilities (DOR).
KNOWLEDGE GAP
The civil works for a solar plant typically requires the application of common engineering practices.

However, given the significant land usage required for large scale solar PV installations, upfront
consideration of civil work scope and cost ensures not only suitable civil design for operations of the
plant, but that the impacts of ongoing maintenance and weather‐related delays are mitigated to
ensure construction schedules and budgets are maintained.

PHOTO: Aerial photograph showing different elements of the civil works package.

5(B) – Structural works


Structural Works

KEY LEARNINGS

Significant learnings were made relating to the transportation and installation of structural
components across the Nyngan site.
In the attached aerial photo, posts can be seen on the side of the internal road adjacent to the
arrays where they will be used. The posts were delivered from offsite directly to the locations,
eliminating the need to move them from a central stores area to the work site.
Tele‐handlers needed only to travel short distances to move the materials from this pre‐staging
point to the exact location in the array where the structures were installed. First Solar accounted for
this vehicle movement when designing the minimum width of alleyways and perimeter roads.
Proper alignment of structures was achieved by installing the end posts within an array, prior to the
internal posts. This provided a fixed point for controlling the line and height via laser. This approach
also enabled electrical works, including underground trenching, to commence as early as possible.
Note that although Nyngan and Broken Hill use the same folding table structure, the post installation
at Broken Hill was more complex due to 15% of posts encountering rocky formations, reinforcing the
impact site conditions play in project execution.
Strict quality control during installation of posts and tilt brackets ensured fewer issues arise later. If
the posts are properly installed then table and module installation is relatively simple and repetitive.
For example, at Broken Hill, with its undulating landscape, in order to ensure ease of table and
module installation there were limits on the number and extent of gradient changes within a row.
Each individual post height was determined from detailed topographic surveys, reviewed and signed
off prior to post installation. Once installed, post spacing, alignment and angle are all checked to
ensure that the structures they support will be easy to install.
Tables at Nyngan were installed using normal tele‐handlers (refer to attached photo) moving
perpendicular to the rows. Thus the tables were presented to the workers parallel to the rows
minimising worker handling. At Broken Hill machinery had to move parallel to the rows because of
the drainage channels, so to avoid workers lifting and turning while carrying the tables side‐loading
forklifts were used.
First Solar found that dedicating teams to particular activities (such as post, tilt, table installation)
improved efficiency as the team was able to establish a routine. However, workers within each
team were still required to regularly rotate tasks in order to avoid repetitive strain injuries, as well as
errors resulting from repetition of tasks.
The tenderers for the Broken Hill contracts were given access to Nyngan where they viewed the
different activities and had access to personnel to ask questions.
At Nyngan four post driving machines (three in operation and one on standby) were sufficient for
the works. At Broken Hill, the sub‐contractor supplemented the three machines provided by First
Solar with an addition three of their own. The machines were serviced and inspected every hundred
hours, with approximately 2‐3 hours downtime – minimal impact on cost and schedule.
 Importance of upfront planning with respect to transportation logistics, for the direct
delivery of equipment to work zones to increase installation efficiency and reduced internal
transportation requirements.
 Structural works execution planning to reduce installation timeline, increase installation
quality through post alignment methodologies, installer specialisation and ongoing quality
checks should be considered upfront and assessed throughout construction.
 Develop clearly defined and documented scope of works and divisions of responsibilities.
KNOWLEDGE GAP

Nyngan and Broken Hill have the advantage of using similar module structures allowing for direct
transfer of installation methodology and lessons learned from site to site, and installer to installer.
Although any project will allow a methodology and routine to develop throughout construction, new
racking systems will often require a ramp up in installation efficiency at the beginning of
construction as installers learn a new installation technique.


PHOTO: Aerial photo showing staging of posts adjacent to arrays where they will be installed.

Photo: Pre‐staging of end tables to the work area

Photo: Pre‐staging of harnesses to the work area

5(C) – Electrical works, including solar PV module installation


Electrical Works (including module installation)

KEY LEARNINGS

The solar modules are shipped as 50 modules per pallet. Each module pallet was staged close to the
area in which they were needed for installation, similar to pre‐staging of the structural materials.
This boosted installation efficiency and also provided traceability and cross‐checking that modules
had been correctly allocated, as the module pallets were scanned in the pre‐staged location.

Use of a template bar during module install was useful to ensure correct module spacing. Over time
the module installation crews achieved significant productivity increases through development of a
working system. One module crew would move ahead and temporarily place modules in the bottom
2 rows. This was quicker than installing modules directly from the pallet. Productivity increased
from 160 to 300 modules per person, per day. Depending on crew size, this translated to a total
module installation of between 6,000 to 11,000 modules per day.

The same module install crew transferred from Nyngan to Broken Hill in order to take advantage of
the skills already learnt.

The development of bespoke wheeled chairs and trolleys (see attached photo) for the module
termination crews increased productivity while providing a more ergonomic work environment.

Most high‐volume tasks involving modules and other electrical components unique to Solar PV have
been designed to be carried out by semi‐skilled labour rather than trained electricians. Other
electrical tasks are similar to those in other applications, e.g. cable terminations, and it is more
efficient to use specialist sub‐contractors than to hire and train staff specifically for the project.

With the drainage channels at Broken Hill, once tables were on and the cable trenches were dug,
there was no access to some rows, so modules were placed in the rows prior to the digging of the
cable trenches.
 Importance of upfront planning with respect to transportation logistics, including planning for
direct delivery of equipment to work zones to increase efficiency of installation and reduced
internal transportation requirements.
 Improvements can be made in sequencing and planning of the structural and electrical works
 Module installation work methods to increase installation efficiency and quality can be carried
through to future projects, including installation tooling, work staging and ergonomic
assistance.
 Ensure access to materials throughout the build, given trenching and natural topographical
features, to allow work to progress along multiple fronts.
 Develop clearly defined and documented scope of works and divisions of responsibilities for
specialist sub‐contractors.
 The protective bags covering the module pallet deteriorate over time with high winds and rain.
This required the pallet to be re‐covered and presents an opportunity for packing improvement.
KNOWLEDGE GAP
Electrical installation activities unique to Solar PV are not complex and there is growing local
experience in Solar PV electrical installation.

Logistical approaches to improving efficiency are not unique to Solar PV.

BACKGROUND
Nyngan and Broken Hill required the installation of approximately 1.36 million and 677,760 solar PV
modules, respectively. Modules are connected in series into strings; the strings from (typically)
three rows are combined at the combiner boxes. The output from (typically) eight combiner boxes
feed into a single inverter, and two inverters with their transformer form a single array with a
generating capacity of approximately 1.3 MW.

The AC collector and Back of Plant (BOP) system is similar to that of a wind farm.

As the technology is relatively straight‐forward the main construction concern is logistics. Hence
considerable planning is required to ensure that the equipment is ordered, delivered and installed
progressively. This is to ensure that there are no inefficient movement of equipment at the factory,
port, road transport depot and on site. Poor logistic management can significantly delay
construction. This planning will include the best port and road network for the delivery method and
ensures roads and accesses are maintained properly to accommodate the high traffic movements,
hence reducing any delays to the construction program.


Photo: Three x Wheel Chair for Enabling Connection of Modules

5(D) – Community Engagement


Community Engagement

KEY LEARNINGS
Stakeholder interest
Community engagement is critical to the successful delivery of large infrastructure projects such as the
Nyngan and Broken Hill Solar Plants. Support from the local communities and key stakeholders for the
Nyngan and Broken Hill Solar Plants has been very positive overall, with the communities highly
engaged and supportive of the projects.
This involved early engagement with the community and key stakeholders as part of developing the
plan which has required a focused effort to implement.
The Nyngan and Broken Hill Solar Plants generated significant interest within the local community and
also at a regional, state and national level. Senior key stakeholders, political dignitaries, interest groups,
community groups and media outlets were all very keen to visit the solar plants during the
construction, which in turn generated further interest from other stakeholders and interest groups.
To accommodate these requests (where possible) during the construction phase of the project required
significant effort and time in order to coordinate with construction activities at site. However, it was
through facilitating these visits that knowledge sharing of the project, and more broadly, information
on renewable energy, has helped to enhance the reputation of those involved with the project. These
visits provided an opportunity to not only showcase the solar plant, but also the local community and
businesses which provided further economic benefits and hopefully future benefits in the long term.
Worker behaviour in host communities
Worker behaviour reflects on the individual, their organisation and also the project. Consequently, it is
critical that workers understand that we are guests in the local community and need to be respectful.
For the Nyngan Solar Plant, the Contractor established a “solar village” to provide additional
accommodation for the construction workers. This was located in the town centre, which helped to
provide increased economic benefits to the community. As part of initiatives to normalise relationships
between solar plant workers and the Nyngan community an open day and BBQ was held at the solar
village; to help the community “visit the village” and “meet the team”. This helped for the local
community to better understand the project and see what was happening for themselves.
For the Broken Hill Solar Plant the local police were encouraged to participate in the ‘toolbox’ talks and
inductions to ensure everyone understood their expectations for visitors working and living in Broken
Hill.

Community engagement meetings
Community engagement meetings were tailored to meet the requirements of the individual
communities at both Nyngan and Broken Hill.
The Nyngan community were keen to be involved in a formal community consultative committee (CCC)
process which regularly involved 11 community members on the committee.
However, the Broken Hill community preferred a less formal process that involved less commitment
from individuals in the community, but the regular community information sessions allowed people to
get involved on an ‘as interested’ basis.
In both cases the meetings were open to the general public, which resulted in a good mix of regulars,
new community members and tourists at each meeting.
Being prepared to be flexible to meet the needs of the locals, and adjust the consultation style resulted
in engaged and informed communities at both locations.
Local employment expectations
Employment opportunities in regional communities can be a difficult. As a result, major infrastructure
projects like the Nyngan and Broken Hill Solar Plants create a high expectation of employment.
It is important to engage with local employment agencies early and establish a link with them and the
Contractors looking to source workers. These agencies can help to match the skills of the local workers
with those being sort by the Contractors.
Early engagement will also provide an opportunity for any project specific training. Local employment
benefits both the local community, the Contractor and the project.
Advertising for local workers needs to consider a range of channels. For example, local print media,
flyers in local employment agencies and supermarkets, radio and websites were used. It is important
that all enquires are responded to in a timely manner and applicants kept informed of any changes.

 Similar to other large infrastructure projects, it is critical that experienced community
engagement personnel are allocated to the project at an early stage.
 In addition to allocating appropriate numbers of experienced community engagement
professionals within the EPC and developer teams, co‐ordinated upfront planning is required to
ensure timely, best practise delivery of community engagement.
 As large‐scale renewable projects are typically located in regional areas consideration needs to
be given to the distance and time required to deliver the community engagement activities.
 Trust is built up if the same person(s) build and maintain relationships with local businesses and
community leaders, attend the local AgFair and open days, and facilitate site visits.
 Allow flexibility with community engagement activities. What might work in one community,
might not be suitable for another community. The formal CCC meetings held in Nyngan were
changed to a more informal engagement approach for Broken Hill.
 Develop a local employment participation plan to help manage local community employment
expectations.
 Be aware of the impact on a local community that the increased worker influx can have on
small communities. This needs appropriate resources to manage.
 Controlled visits of the solar plants and (Nyngan) solar village helped with community
engagement with locals being able to better relate to the project.
KNOWLEDGE GAP
Development of the Nyngan and Broken Hill Solar Plants has signalled the birth of large‐scale solar in
Australia. This generated significant interest within the local communities, as well as with key
stakeholders, media and the wider community on a national level and provided an important
knowledge sharing opportunity.

As large‐scale renewable projects become more common broader interest may wane. However, since
such projects are typically located in regional areas, interest in projects will be proportional to the likely
economic impact on the community and their interest will be on how the specific project will affect
them.

ADDITIONAL PROJECT INFORMATION
Nyngan Solar Plant
https://www.agl.com.au/about‐agl/how‐we‐source‐energy/renewable‐energy/nyngan‐solar‐plant

Broken Hill Solar Plant
https://www.agl.com.au/about‐agl/how‐we‐source‐energy/renewable‐energy/broken‐hill‐solar‐
plant

Broken Hill Solar Plant aerial video
https://www.youtube.com/watch?v=GHQnlQsX3KQ

Jeremy Buckingham MP, Greens Nyngan Solar Plant video
https://www.youtube.com/watch?v=tqcX‐H2OZKc

Photos: Examples of community and key stakeholder participation Nyngan and Broken Hill solar plants


Feedback and areas for improvement – Nyngan and Broken Hill Solar PV


Knowledge Type: Other (please specify):
Commissioning
6H
Demobilisation

KEY LEARNING
Demobilisation planning commenced some months prior to the end of construction and
commissioning and included:
 Preparing a layout of the facility during the operational phase
 Identifying any hardstands or laydown areas that did not need to be rehabilitated
 Identifying structures, materials and equipment that needed to be moved or demobilised
 Planning when each activity could take place
 Identifying who would be responsible for each activity

The timing of demobilisation activities depended on punch list items being closed out.

The IT infrastructure at Nyngan and Broken Hill was embedded in the commissioning building, which
prevented demobilisation of the building until alternate IT connections could be constructed. If the
operational phase needs and temporary nature of the construction‐phase buildings had been
considered at the outset then the IT infrastructure could have been installed once and had no
impact on demobilisation.

Considering the location of hardstands at the outset – placing them where they could be used during
the operational phase of the plant – could have reduced the area that needed to be regenerated.

At Broken Hill material excavated for cabling was used to fill in the temporary dam.


There are opportunities at the outset to leverage off operational‐phase infrastructure during the
construction phase.

KNOWLEDGE GAP
None.

None.




KEY LEARNING
The Operating Protocol is an agreement between the generator and the NSP that outlines the
procedures to be followed for safe and efficient operation. It typically covers:
 Operational boundaries
 Operational responsibilities
 Notification processes
 Communication processes
 Switching for planned works
 Switching for emergency conditions
 Special conditions

Both Nyngan and Broken Hill had special operational conditions (unrelated to solar) that needed to
be understood by both parties.

While the Operating Protocol may be anticipated in the Connection Agreement it is a stand‐alone
document.

The Operating Protocols need to be finalised prior to the commencement of operations. For both
Nyngan and Broken Hill the Operating Protocols were finalised more than 3 months before any
generation.

Discuss the process for developing the Operating Protocol with the NSP and their timing
expectations well in advance of generator completion, allowing one month for preparation of the
protocol.

KNOWLEDGE GAP
None. The Operating Protocol is based on pro‐forma documents provided by the NSP. There is little
difference in the Operating Protocols applied to solar compared to other types of generating assets.

Essential Energy has a library of documents related to HV connections:
http://www.essentialenergy.com.au/content/hv‐connections‐documents

The document CEOP8079 ‐ Connection Process includes a section on the HV Operating Protocol:
http://www.essentialenergy.com.au/asset/cms/pdf/contestableWorks/CEOP8079.pdf

Essential Energy also provides a Sample Operating Protocol:
https://www.essentialenergy.com.au/asset/cms/pdf/hv/SampleOperatingProtocol.pdf



Commissioning

KEY LEARNING
The PV Plant SCADA system provides supervisory control and data collecting capabilities. This data
mainly consists of the status of equipment (on/off etc) and analogue quantities such as volts, amps
and watts etc. This data is collected from key points in the field that will support the observation,
operation and control of the plant. The entire list of data points is generally termed the I/O list as it
records the inputs (I) and outputs (O) for the plant. The SCADA system then arranges this data into
sets that can then be used by different Stakeholders. These sets constitute the data that each SCADA
Stakeholder will be given for their required purposes. For example AGL will require all of the
operational control inputs and outputs, and analogue outputs to effectively operate the plant. The
NSP may only want to view the analogue outputs as it does not operate any portion of the plant.
Hence different sets of data are created and sent to each Stakeholder as required.

The data collected includes:
 Generation data (P, Q, V, I) for the site
 Generation data for individual inverters
 Meteorological Data (solar insolation, temperature etc.)
 Statuses and alarms
 Power data from the NSP

As Nyngan and Broken Hill were the first large‐scale solar projects to be connected to the AEMO
grid, coordination and early planning with all stakeholders has been identified as critical to the
smooth commissioning of the plant. In particular, the I/O list should be agreed among all parties as
early as possible. This would allow time for all of the necessary iterations to occur.

First Solar commissioned the SCADA system and engaged a local firm specialised in automation and
controls to assist in the commissioning field work for the hardware. This proved to be an excellent
combination that added the necessary manpower and experience required during this phase of the
project.

With data being shared between a large number of stakeholders, strong coordination and early
preparation is required to get everything tested in a short time frame. By using the same contractor
at both Nyngan and Broken Hill, these staff were already familiar with the design and procedures.
This significantly reduced First Solar’s internal costs as less commissioning staff from the USA were
required.

In order to take advantage of key learnings, it is important to maintain consistency in SCADA system
design. This leads to efficiency not only in commissioning, but also in operation.

Further efficiencies could be gained by developing a standard I/O list for solar plants that is agreed
by AEMO and the various NSP’s.

While there are unique aspects for every site depending on the connection arrangement, there are
core requirements for meteorological data (average solar insolation, average ambient temperature)
and plant output at the point of connection (phase & average active power, reactive power, voltage,
current, power factor, set points, operating modes, main breaker statuses) the could easily be
standardised. Alternately, a guideline similar to the existing AEMO guidelines for semi‐scheduled
generators could be put in place specifically for solar power plants.

KNOWLEDGE GAP
Apart from solar‐specific meteorological data, there is little difference in SCADA systems applied to
solar compared to other types of generating assets.

None.



Commissioning

KEY LEARNING
In partnership with the Power Plant Controller (PPC), the inverters provide the performance that the
solar plant requires for National Electricity Rules (NER) registration and compliance. The inverters
are one of the most complex parts of the solar plant, and require a large amount of analysis prior to
commissioning and operation. This analysis was performed by using specialised software (eg.
Siemen’s Power System Simulation for Engineering (PSS/E)) modelling to determine the theoretical
performance and response of the inverters (selection of settings) and PPC prior to operation. This
established the performance criteria for NER registration and compliance. The knowledge of the
settings gained by this analysis was then transferred into the actual inverters firmware (via the
inverter model settings list) prior to commissioning, to ensure that the actual inverters performed in
accordance with the NER requirements. The theoretical performance of the inverters was reviewed
by the NSP to confirm stable network operation. Hence the commissioning of the inverters allowed
the validation of the inverter settings (hence NER requirements) to occur.

The commissioning of the inverters was greatly assisted by selecting a partner (inverter
supplier/manufacturer) with a strong local field servicing team, and ensuring that some key spare
components were available on site or readily obtainable.

It was found that it is essential to provide a full list of inverter settings to the NSP at an early stage,
since all settings may not be captured in the PSS/E model.

It was found at Nyngan that a clear map between inverter model settings and the firmware settings
did not exist (i.e. it was unclear from the inverter PSS/E model documentation how to choose
equivalent firmware settings that would ensure the inverters provided matching performance to the
simulations when operating in the field. To remedy this, a settings map was developed in
cooperation with the inverter manufacturer as part of the Broken Hill commissioning.

In future projects, the inverter’s complete firmware parameter list should be submitted as an
attachment to the R1 data, along with a map to corresponding model settings. This will help to
ensure consistency between the simulation and actual plant performance, and reduce the risk of
needing to make adjustments to the inverter settings later in the commissioning.

KNOWLEDGE GAP
A number of different inverter manufacturers have been found to have limited knowledge of the
AEMO registration process and the model accuracy requirements. Compared with other energy
markets overseas, Australia’s modelling and validation process appears to be significantly more
rigorous.

Generally speaking, First Solar has not seen clear documentation from inverter manufacturers that
provides a detailed settings map between firmware and their PSS/E model. This is a significant front‐
end project risk that may be relevant for all inverter manufacturers, since very few have experience
in the Australian market.

However, First Solar has subsequently noticed that some networks in the USA are adopting a similar
regulatory approach to that used by AEMO, which should reduce the knowledge gap for Australian
developers.

None.



Commissioning

KEY LEARNING
The Photovoltaic Combiner Switchgear (PVCS) and Photovoltaic Integrator Switchgear (PVIS):
 Collect the energy produced by the inverters and converges it at the Point of Connection,
 Provide protection for the HV AC cables via circuit breakers and protection relays,
 Provide input into the metering and control of the power production via Current
Transformers (CTs) and Voltage Transformers (VTs), and
 House SCADA equipment, fire detection systems, and auxiliary power from an auxiliary
transformer.

A PVCS contains circuit breakers for a number of “Way Feeders” (3 per block at Nyngan and 4 per
block at Broken Hill) that collect high voltage power from the “Ways”. Each Way Feeder is made up
of several Power Conversion Stations (PCS) connected in series. Each PCS contains a Ring Main Unit
(RMU), step‐up transformer, a pair of inverters. The PVCS has an incomer circuit breaker that
connects the PVCS to one of the “Block Feeders” circuit breaker at the PVIS. At Broken Hill, the PVCS
is used to connect the solar plant to the Point of Connection at the Broken Hill Substation via a 22kV
OHL.

At Nyngan the PVIS connects the solar plant to the Point of Connection via the 132/33kV
transformer.

The PVCS and PVIS are similar to switchgear arrangements used by other modular generators, such
as wind farms. At Nyngan and Broken Hill, the PVCS’s were designed by different local 3rd parties. A
key lesson learned was that changes to the Generator Performance Standards (GPS) that impact the
inverter protection will also impact the PVCS protection schemes, and that this can have a significant
project impact through the need to coordinate with third parties to revise and test relay protection
settings.

It was also found that the access door designs at Broken Hill (single‐person hinged door, sealed with
a locking handle compared to a simple roller door design at Nyngan) provided significantly better
protection against dust ingress and provided an all‐weather environment for personnel during the
operating phase of the plant.

Some of the advantages of having a PVIS in addition to PVCSs at a site such as Nyngan are:
 Improved protection of AC cables,
 Provides a level of redundancy when equipment fails,
 Reduces availability losses during maintenance, for example, to perform work on an RMU, it
can be isolated at the PVCS feeder, isolating a way feeder, rather than de‐energising the
entire block at the PVIS.

However, the solar industry is moving to designs that contain less intermediate switchgear, as the
availability gains from redundant equipment have not proven to justify the additional capital
(including materials, engineering, installation, and commissioning) and maintenance costs that come
with increased complexity of the plant design.

Due to the large number of different technical elements involved in delivery and commissioning the
PVCS and PVIS (including civil, mechanical, AC and DC electrical, fire detection and suppression, and
SCADA) a key challenge was coordinating between the various 3rd parties and ensuring that the
complete scope was implemented in full without any gaps in responsibility. This experience will drive
additional attention and detail in the subcontractor scope of the PVIS and PVCS on future projects.

Whilst the PVCS design at BH delivers some improvements over Nyngan, they are not directly
comparable as the BH PVCS’s included several features of the Nyngan PVIS and enjoyed a larger
budget allocation due to the site not having a PVIS. In future, we would recommend to avoid roller‐
door designs since the door design at Broken Hill delivers improved dust protection at negligible
additional cost.

KNOWLEDGE GAP
None.

None.




Commissioning

KEY LEARNING
Key aspects of the commissioning process that required interface with the Network Service Provider
(NSP) were:
 Connection Agreement and agreed performance standards in place.
 Preparation of the Commissioning Plan.
 Demonstration that the site was ready to energise – this was achieved through:
o Submission of Generator Performance Standards (GPS) and associated technical
studies
o Connection Agreement between AGL and the NSP
o Commissioning Plan and GPS Test Plan
o Operating Protocol between AGL and the NSP)
o NSP notices (e.g notices to the NSP for testing and commissioning)
o Submission of design documentation
o Certificates of Installation Compliance to AS3000
o Certificates of Design Compliance to AS2067,
o Protection test reports
o Calibration certificates associated with testing equipment
o Installation inspection by an NSP representative prior to energization.
 Inspection of the HV equipment to be energised by a representative of the NSP.
 Coordination with the NSP Control Centre.
 AC back‐feed from the PVIS incomer to the PVCSs and inverter AC circuit breaker.
 First export (inverter AC commissioning) to the grid in accordance with the Commissioning
Plan.
 Satisfactory completion of all commissioning tests (SCADA, GPS, etc.) involving generation
that might impact the network.
 Permanent connection and ongoing generation.
 Day‐to‐day operation of the solar farm.

For each of these items, minimum notice‐periods apply, which need to be considered in order to
avoid the notice period adversely impacting the project schedule. However, it can be difficult during
commissioning to adhere strictly to the schedule, but this ensures the best chance of guaranteeing
NSP availability.

Introductions between commissioning staff and the NSP early‐on, contact sheet (details of key
personnel), and communication protocols all assisted with coordination and ensured information
was shared efficiently.

It was found that additional time needs to be allowed for any works involving NSP assets due to
limited availability of NSP personnel, particularly in regional areas where a small number of staff
service a very large network area. Furthermore, time needs to be allowed to become familiar with
the specific requirements of each NSP for each specific project ‐ as the requirements, engagement
and relationship with Essential Energy for Nyngan and TransGrid for Broken Hill differed in several
key ways, including:

‐ TransGrid took a more active role in determining the inverter and plant controller settings,
and made requests for changes to the Connection Studies at a late stage in the project.
‐ Nyngan was required to implement an Emergency Runback Scheme, which needed to be
designed and commissioned in cooperation with Essential Energy.
‐ In the case of Broken Hill, getting access to the Connection Point at the TransGrid substation
for installation of a continuous high‐speed meter required a First Solar staff member to
undergo several days of training. Arranging for TransGrid to have staff at the substation for
implementing line current differential settings was also a task that had significant lead time
(~3 months).
‐ AEMO and Essential Energy disagreed over several aspects of the GPS Compliance Test Plan,
and reaching an agreement took over 1 month, with the desire to completely asses GPS
Compliance in conflict with the stability of the network. A low‐load period during
commissioning also required the project to wait several weeks before performing some
tests.

With the advantage of hindsight, many of the above challenges could have been managed or
mitigated through earlier, more active engagement with the NSP. Based on experience it seems
likely that future projects would encounter similar difficulties, all of which are manageable provided
that sufficient time is allowed and that this aspect of the commissioning process is prioritised
accordingly.

The commissioning plan and test procedures should be:
 Developed in cooperation with the NSP at least 3 months prior to commissioning,
 Need to identify all activities that involve the NSP, and
 Should aim to schedule dates for these activities at least 1 month in advance

Make allowance in the schedule for the unpredictable nature of commissioning impacting on fixed
dates agreed with the NSP.

KNOWLEDGE GAP
A general lack of experience commissioning large‐scale solar farms in Australia on all sides
contributed to the time frames that were necessary for the coordination around commissioning
activities.

In future, as NSP’s become more familiar with the modular nature of the commissioning process
(export coming on block by block) and the nature of control requirements for a generator whose
output is highly variable, the process for agreeing settings and commissioning procedures will
become more efficient.

None.



Commissioning

KEY LEARNING
Both solar plants are located in remote areas of the network where the grid was very sensitive to the
solar plant’s performance. As a result, it was found that First Solar’s standard commissioning tests
and the Generator Performance Standards (GPS) compliance tests for the solar plant occasionally
conflicted due to network stability requirements, for example testing the full reactive capability of
the plant would have pushed the local network voltage out of range. In some cases it was not
possible to perform the tests or the tests needed to be done across a much narrower performance
range. To address this, it was necessary to coordinate with both AEMO and the NSP to either reduce
the testing scope, or arrange a time to perform the test when the network was more robust, or
provide alternative data to satisfy the requirements.

It was found that with less data available on remote areas of the network, it was very important to
take pre‐generation quality of electricity measurements so that the impact of the solar plant could be
accurately assessed.

After experience at Nyngan where there was less engagement with the NSP with regards to the
AEMO commissioning program, development of this plan in close cooperation with TransGrid
ensured that the testing went more smoothly, and reporting could be completed more quickly.

First Solar planned its commissioning activities based on its experience in the USA and other markets.
AEMO commissioning requirements require accurate validation of a user‐written Power System
Simulation for Engineers (PSS/E) model through overlays of high‐speed test and simulation data. First
Solar contracted the services of a local consultant to assist in managing compliance AEMO
requirements, however the scope was not fully understood in the early stages which led to gaps later
on.

The requirement for PSS/E model overlays during the GPS testing (and later R2 validation to 10%
accuracy) also highlighted a failure to consider the impact of the power plant controller on the PV
plant response. In combination with this, numerous deficiencies were identified with the accuracy of
the inverter model, which only came to light once the commissioning process had begun. This led to
extensive delays in completing GPS and R2 testing as multiple iterations of the inverter model and
firmware were needed in order to improve their accuracy and meet the requirements.

It was also found that whilst the meters in the original design were suitable for ongoing compliance
monitoring, they lacked several features that are preferred for validation of the AEMO requirements,
such as continuous monitoring at 1ms intervals.

As a consequence of the solar plant being built in stages with a large number of small generators
(inverters), it was found that the original version of the GPS Commissioning Plan misinterpreted
inverter availability at the various hold points. For example, the plan expected the plant to generate
full Reactive Power at 50% Active Power, except that with only half of the inverters online this
effectively halves the reactive capability of the plant.

A thorough understanding of the AEMO requirements is required prior to any work (including the
GPS) being submitted to AEMO. Time needs to be allowed for development of commissioning and
GPS compliance test plans in cooperation with the NSP – the current requirement is 3 months prior
to commissioning, but we would recommend presenting a draft several months prior to this to
ensure there is time for multiple iterations.

This phase of the project can have significant impact on project timelines and should receive
appropriate attention from the outset. This would include holding detailed design review meetings
with the NSP and AEMO during the modelling stage of the project, to ensure consistency between
the Generator Performance Standards and the intended design of the plant.

KNOWLEDGE GAP
The lessons learned show that knowledge gaps existed among all parties, largely as a consequence of
these projects being the first utility‐scale solar farms to connect to the NEM, and several of the
players involved going through the process for the first time.

The main residual knowledge gap exists around the inverter, which has several unique characteristics
for solar power. It was found that the details of the inverter fault‐ride‐through behaviour were not
well understood, or sufficiently represented by the PSS/E model and corresponding documentation
(provided by the inverter manufacturer). Failure to identify modelling inadequacies in the
Connection Study combined with unfamiliarity of the AEMO commissioning requirements created
significant challenges for the project. It is likely that other project developers and inverter
manufacturers who lack experience in the Australian utility‐scale market will face similar challenges
unless they invest in early and sustained engagement with local, suitably‐experienced, consulting
firms and directly with AEMO.

AEMO Completion Requirements
http://www.aemo.com.au/Electricity/Network‐Connections/NEM_Generator_Distribution_New‐
Connection/Stage‐6

AEMO National Electricity Rules
http://www.aemo.com.au/About‐the‐Industry/Legislation/National‐Electricity‐Rules

AEMO Generating System model Guidelines
http://www.bing.com/search?q=aemo+generating+system+model+guidelines&src=IE‐
TopResult&FORM=IETR02&conversationid=

AEMO Reliability Standards Implementation Guidelines
http://www.aemo.com.au/Consultations/National‐Electricity‐Market/Reliability‐standard‐
implementation‐guidelines

AEMO Technical Information Requirements for Generators
http://aemo.com.au/Reports‐and‐Documents/network‐connections/Technical‐Information‐
Requirements‐for‐Generator‐Transmission‐Connections‐in‐Victoria

AEMO R2 Testing Guidelines
http://www.aemo.com.au/Electricity/Policies‐and‐Procedures/R2‐Testing‐Guideline



Commissioning

KEY LEARNING
The Capacity Test is performed for each Block in the Solar Plant once it has been brought up to full
power and any initial DC Health issues (disconnected leads, etc.) have been rectified. The purpose of
the Capacity Test is to confirm that the plant will generate its contracted AC output capacity. This is
measured at the Connection Point, with agreed corrections made for temperature and irradiance
variations. This is to allow for differences in the DC output of the actual PV modules versus Standard
Test Conditions on which the contracted amount is based.

Whilst the Capacity Test is not a direct measure of the energy that a PV plant is likely to produce
over its lifetime, the fast and simple test is used to demonstrate to the Principal that the plant is
capable of delivering its nameplate AC capacity at the Connection Point. This was agreed as an
acceptable starting point from which Practical Completion was granted and the year‐long
performance tests could commence.

The test procedures followed at Nyngan and Broken Hill were standardised procedures developed by
First Solar. Given their ubiquity within First Solar there were no further learning opportunities or
improvements to the procedure.

The test procedure used for determining the minimum capacity of the plant should be agreed
between the owner/ developer and the Principal Contractor and appended to the contract.

KNOWLEDGE GAP
Procedures for confirming the installed capacity of solar plants vary somewhat across the industry,
as there are a number of different methods for assessing that a plant will perform in accordance
with its design (Laboratory module tests, Capacity Test, Performance Ratio, Energy Guarantee, etc.).

In order to assure consistency in the quality of design and performance of PV plants that receive
funding from ARENA and to ensure that funding is distributed to projects in a fair and equitable
manner, it would be advisable to have a standard procedure, such as an industry wide “Standard
Capacity Test”. This would ensure that plants are built to deliver their intended AC capacity at the
Connection Point under normal operating conditions, rather than just the inverter nominal power at
25°C and unity power factor.

IEC 61646 ‐ Thin‐film terrestrial photovoltaic (PV) modules ‐ Design qualification and type approval

IEC 60904 ‐ Photovoltaic devices ‐ ALL PARTS



Commissioning
6H
Demobilisation

KEY LEARNING
Demobilisation planning commenced some months prior to the end of construction and
commissioning and included:
 Preparing a layout of the facility during the operational phase
 Identifying any hardstands or laydown areas that did not need to be rehabilitated
 Identifying structures, materials and equipment that needed to be moved or demobilised
 Planning when each activity could take place
 Identifying who would be responsible for each activity

The timing of demobilisation activities depended on punch list items being closed out.

The IT infrastructure at Nyngan and Broken Hill was embedded in the commissioning building, which
prevented demobilisation of the building until alternate IT connections could be constructed. If the
operational phase needs and temporary nature of the construction‐phase buildings had been
considered at the outset then the IT infrastructure could have been installed once and had no
impact on demobilisation.

Considering the location of hardstands at the outset – placing them where they could be used during
the operational phase of the plant – could have reduced the area that needed to be regenerated.

At Broken Hill material excavated for cabling was used to fill in the temporary dam.


There are opportunities at the outset to leverage off operational‐phase infrastructure during the
construction phase.

KNOWLEDGE GAP
None.

None.



Knowledge Type: Other (please specify): Operations and Maintenance

KEY LEARNING
Given that Nyngan and Broken Hill were one of the first Australian utility scale solar plants to be
commissioned, there was no pool of experienced operators to draw from, or external educational
institutions providing comprehensive training to be found locally.

Operators are expected to:
 Monitor operation of the plant
 Plan maintenance activities – sampling, testing, adjustment, calibration, etc.
 Carry out planned and unplanned maintenance and upgrades of equipment and the plant
 Respond to Plant alarms, while on site or on call
 Liaise with Network Operators

Particular knowledge/ experience needed are:
 Knowledge of solar plant operations
 Understanding of electrical characteristics of photovoltaics including live working during all
daylight hours
 HV switching certification/ credentials

First Solar began the recruitment process during construction, focussing on construction personnel –
who would have gained some understanding of the plants from their work during construction – and
the local community. In addition, First Solar was looking for personnel with a good electrical
background and preferably with HV Network experience.

There were advantages to this approach (selecting from personnel who had been part of
construction and commissioning), including:
 Recruits had an understanding of the operation of the plant
 Early interaction with the SCADA system gave insight into the components and interfaces
 Familiarity with the switching sequence for the plant, which differs from a standard network
 Allowing consistent lock out and isolation procedures to be rolled out from construction
though to operation
 Allowing operations staff to establish and form relationships with Network operators prior
to the operation of the plant.

Training aspects for the Operators consisted of internal First Solar training and external training and
experience. First Solar provided on the job training from (foreign) experienced staff and First Solar’s
web based training modules. This focussed on understanding of the technical aspects of solar plant
equipment and its operation. External training, included:
 HV switching/switch gear operation
 Understanding of the protection system – specific detailed training provided by equipment
suppliers, e.g. Siemens
 First aid, resuscitation

Given the absence of experienced operators and third‐party providers of solar plant operator
training, the burden of training operators will fall on the plant’s operators.

There are significant benefits to recruiting from among personnel involved in the commissioning of
the plant, or involving candidate operators in the commissioning of the plant.

KNOWLEDGE GAP
While some operator skills are generic (e.g. first aid) or can be transferred from other industries (HV
switching), there are other aspects that are specific to solar plant operation, including:
 Understanding of electrical characteristics of photovoltaics
 Knowledge of switching sequences
 Protection




7B Maintenance

KEY LEARNING

First Solar operations personnel undertake all required maintenance activities and carry out trouble‐
shooting of major issues with support from local and international First Solar resources.

Some maintenance services are contracted out locally and include:
 Fire systems maintenance
 Provision of plant – generators, cranes, forklifts, graders
 Vegetation control – chemical and mechanical
 Pest Control
 IT services

Further maintenance services are contracted out to Australian service providers, outside the local
region and include:
 Transformer maintenance, oil sampling
 Specialist circuit breaker services
 Protection systems checks and settings
 Other testing services
 Inverter maintenance/repairs
 Equipment calibration

The efficiency of the maintenance and subsequent performance of the plant is based on a number of
critical factors. These factors include the timing of response by sub‐contractors, quality of the service
and staff knowledge and understanding.

The timing of services is affected by the location of the Plant. Local staff can respond in a short
timeframe, but services from outside the region take longer to reach the site so there could be a one
day delay or more while personnel travel to the site.

In general the quality of services is good. Many of the companies used for O&M services were also
used during construction and this allowed their capabilities and service levels to be assessed prior to
maintenance contracts being issued.

SCADA systems are complex, and although O&M staff have a good electrical knowledge additional
training and support is required to provide a better understanding of the SCADA system.

A number of equipment suppliers and their technical support services are located in different time
zones which leads to lag in response times to enquiries and trouble shooting. This needs to be
managed to ensure the smooth operation of the plant.

The ability to switch the HV switchgear locally and remotely via the SCADA interface was different to
what the operators were used to, so specific training was required prior to commencing operations.

Staff also need to be able to coordinate with weather conditions. A variety of vegetation control
measures, both chemical and mechanical, need to be employed. Timing and application of
vegetation control measures needs to be coordinated with weather events to ensure their efficacy.

The location of the plant, the consequential delays in access by service providers and the availability
of spares are critical in the development of spares and maintenance strategies, and what needs
and/or can be performed in house.

Plant operators (who do the routine maintenance) will require training in SCADA and plant
equipment. Operators benefit from experience in the construction and commissioning of the plant.

Involving maintenance management in the construction and commissioning of the plant allows
visibility of service provider capabilities and facilitates the development of relationships with key
service providers.

KNOWLEDGE GAP
Currently, equipment calibration and service personnel for protection equipment, e.g. Siemens
personnel from NZ, are not available from Australia‐based service providers.




7C Operation

KEY LEARNING
AGL dispatches the electricity generated at the Nyngan and Broken Hill solar plants into the NEM.
This occurs during the daylight hours of solar photovoltaic operation. Plant‐based operations
include:
 Monitoring all systems within the plant, including:
o Alarms
o All electrical output
o Irradiance and other climatic information
o Soiling (i.e. the impact of dust build‐up or other fouling of the panels)
o Weather (temperature, wind, rain)
o Grid conditions
 Carry out infrared thermography to identify potential issues

To facilitate these operations, the plant was developed with the following capabilities:
 A complex SCADA system was established to take inputs from a variety of instrumentation
and monitoring equipment.
 Monitoring systems installed included the meteorological stations, soiling stations, reference
modules, temperature clusters on modules, transducers and meters to monitor
temperature, voltage, current, etc.
 Video surveillance is also used for monitoring.

However, we have learned that one cannot rely solely on electronic monitoring. The monitoring
needs to be a combination of SCADA, status reporting and human observation. Examples of where
human observation has been valuable:
 Thermographic imaging of items such as Combiner Boxes has been used to monitor for any
possible heat issues.
 Visual inspections of modules and plant items to assess condition and inform preventative
maintenance needs.
 Security monitoring by security and operating personnel: observing or inspecting the site
boundaries, buildings, etc. for any vandalism or security breaches, and then being
responders to the authorities if any breaches are detected.

Monitoring for operational and reporting requirements needs to be considered as part of the design.

Remote monitoring (enabled by instrumentation and video) needs to be supplemented by direct
observation. This needs to be considered in assessing staffing requirements.

KNOWLEDGE GAP
None.




KEY LEARNING
Aspects of the design that facilitate operation and maintenance activities:
 No moving parts. Minimal maintenance on the structural components.
 Elevated platforms for structures such as the Power Converter Station (PCS), PhotoVoltaic
Combining Switchgear (PVCS) and PhotoVoltaic Interconnection Switchgear (PVIS). The
elevated structure make it easy to access cables to trouble shoot any cable issues. The
elevated structure eliminates enclosed/confined spaces that would require extra operator
training and work procedures.
 Open structures such as the PCS provides plenty of work space and area making it safer to
work on equipment.
 Ring Main Unit (RMU) at each PCS structure. This allows the isolation of a small segment of
the plant rather than a whole Block.
 SCADA system makes it easy to monitor all aspects of the plant.

Aspects of the design that could be improved to facilitate operation and maintenance activities:
 The design of the rooms for some of the switchgear could be improved. The environment
(dust) and access to the switchgear in wet weather needs to be considered.
 Consider overhead HV lines from Blocks to PVIS rather than underground cables. Overheads
would be visible and easy to maintain.
 Review road quality and design for all weather access.

It is important to consider the needs of operations and maintenance staff in the design of the plant,
particularly:
 Safe all‐weather access to equipment
 Physical ease of access to equipment, i.e. create adequate access to and space around
equipment to support maintenance activities.
 Electrical ease of access to equipment, i.e. ability to easily isolate small sections of the plant
or to provide access for routine operations or maintenance activities that does not require
isolation.

KNOWLEDGE GAP
None.

C – Knowledge Sharing Certificates

10 Fe brua ry 2014
GP O Box 643
By e ma il Ca nbe rra ACT 2601
T. +61 2 6276 1000
a re na .gov.a u
Mr Ma rk S te phe ns ABN 35931927899
He a d of Cons truction De ve lopme nt
P owe r De ve lopme nt
AGL Ene rgy Ltd
Le ve l 22
101 Mille r S tre e t
North S ydne y NSW 2060
Dear Mark,
RE: Knowledge Sharing Milestone notice No.2
On 10 February 2014 ARENA received a Notice from Mr Doug Landfear stating that
Projectco had fulfilled the requirements for Knowledge Sharing 2.
In accordance with clause 14(c) of the ARENA Funding Agreement I issue this
Knowledge Sharing Milestone Certificate. This Certificate certifies that Projectco has
achieved Knowledge Sharing Milestone 2 as set out in ARENA Contract Q00083 and in
a manner that complies with the knowledge sharing variation deed of 13 December
2013.
In this letter, unless context requires otherwise:
a) “ARENA Funding Agreement” means ARENA Contract Q00083 dated 5 June

2013 between AGL PV Solar Holdings Pty Limited, AGL PV Solar
Developments Pty Limited and the Australian Renewable Energy Agency
(ARENA); and
b) Capitalised terms used in this letter that are defined in the ARENA Funding
Agreement have the same meaning.
Yours s ince re ly,
Amy P hilbrook
As s is ta nt Ma na ge r
La rge S ca le S ola r
11 August 2014
GPO Box 643

By email Canberra ACT 2601
T. +61 2 6276 1000
arena.gov.au
Mr Mark Stephens ABN 35931927899
Head of Construction Development
Power Development
AGL Energy Ltd
Level 22
101 Miller Street
Dear Mark,
On 8 August 2014 ARENA received a Notice from Mr Doug Landfear stating that
Projectco had fulfilled the requirements for Knowledge Sharing 3.
2013.
a) “ARENA Funding Agreement” means ARENA Contract Q00083 dated 5 June

(ARENA); and
Yours sincerely,
Amy Philbrook
Client Manager
Large Scale Solar
Australian Government -e
Australian Renewable Energy Agency Z
ILl
a:
8 April 2016 -e
GPO Box 643
T. -+61 26276 1000
arena.gov.au
Power Development
AGL Energy Ltd
Level 22
101 Miller Street
Dear Mark,
On 5 April 2016 ARENA received a Notice from yourself stating that Projectco had
achieved the requirements for Knowledge Sharing Milestone No.5 (KS5).
2013.
a) "ARENA Funding Agreement" means ARENA Contract Q00083 dated 5 June

Developments Pty Limited and the Australian Renewable EnergyAgency
(ARENA); and
Yours sincerely
Adrian Rule
Manager
Early Deployment
Australian Government III(
Australian Renewable Energy Agency Z
LIJ
a::
12 July 2016 III(
GPO Box 643

T. -+B1 26276 1000
arena.gov.au
Power Development
AGL Energy Ltd
Level 22
101 Miller Street
Dear Mark,
On 11 July 2016 ARENA received a Notice from yourself stating that Projectco had
achieved the requirements for Knowledge Sharing Milestone No.6 (KS6).
achieved Knowledge Sharing Milestone 6 as set out in ARENA Contract A00083
(Q00083) and in a manner that complies with the knowledge sharing variation deed of
13 December 2013.
a) "ARENA Funding Agreement" means ARENA Contract Q00083 dated 5 June

(ARENA); and
Yours sincerely
Adrian Rule
Manager
Early Deployment
D – Knowledge Sharing Workshop Presentation

1
AGL Nyngan and

Broken Hill
Solar PV projects
ARENA Large Scale

Solar Knowledge
Sharing Workshop
Presented by –
Adam Mackett
22 April 2016
2
Nyngan
Solar Nominal 1,366,380
Flagships 102 MWac Series 3
project with Output Black Plus
Broken Hill First Solar
modules
At peak 300 Site is 250 154 SMA Connected

workers on hectares: 800CP XT to Essential
site over 360 Inverters Energy at
NRL fields 132 kV
230,000 77 360V/
MWh/ year 33kV Wilson
= 33,000 Transformers
NSW homes
> AGL Nyngan and Broken Hill Solar PV projects

> Adam Mackett
> 22 April 2016
3
Broken Hill
Solar Nominal 677,000
Flagships 53 MWac Series 4
project with Output Black Plus
Nyngan First Solar
modules
At peak 150 Site is 140 80 SMA Connected

workers on hectares: 800CP XT to TransGrid
site over 200 Inverters at 22 kV
NRL fields
126,000 40 360V/
MWh/ year 22kV Wilson
= 17,000 Transformers
NSW homes

> Adam Mackett
> 22 April 2016
4
Project Participants
AGL
List of parties:
Owner and Developer
› AGL
› First Solar
Owner’s engineer and project management services
› New South Wales
› Commonwealth Government of Australia
› Consolidate Power Projects
Principal Contractor – Power Station
Principal Contractor – Connection Works
Funding Partner ($ 166.7 million)
Funding Partner ($ 64.9 million)

> Adam Mackett
> 22 April 2016
5
Presentation
focuses on
We already
what’s new know a lot
and different about
renewable Downstream of
the inverters,
generation solar plants are
similar to wind
farms – which
the industry
knows how to
develop and build

> Adam Mackett
> 22 April 2016
6
Knowledge Gaps & Implication for Future Projects
1 Development
2 Connection
3 Supply Chain
4 Construction
5 Commissioning

> Adam Mackett
> 22 April 2016
1. Development 7
Site Assessment
Knowledge Gap
› Secondary criteria for site selection
Implications for Future Projects

› Site selection should consider:
» Hydrology – land is usually flat and flood prone
» Geology – impacts cost of structures
» Flora and fauna – protected species affect layout
» Environmental offset – availability if required
» Access to grid – time and effort to get easements
» Road Access – time and effort to approve/ build
» Logistics – access to transport infrastructure
» Labour – accommodation if insufficient local labour
» Utilities – access to utilities, e.g. water
> Adam Mackett
> 22 April 2016
2. Connection 8
Generator Performance Standards
Knowledge Gap
› Local knowledge of inverter technology

› Inverter model defines everything - Fix ASAP
› Prioritise validated PSS/E model
› Engage with NSP and AEMO early to get consensus
on the inputs into technical studies and the GPS
› The process is iterative, allow enough time for
revising studies, and engaging all stakeholders
› Contract strategy should consider including
responsibility for modelling with inverter scope, to:
» Eliminate unnecessary interfaces
» Align control and impact of changes

> Adam Mackett
> 22 April 2016
2. Connection 9
AEMO Registration
Knowledge Gap
› Supplier knowledge of Australian regulations
› Local knowledge of inverter technology
› Implications for NER of solid state generation

› Start early
› Consider and discuss providing auxiliary services –
will impact on scope
› Be ready to educate:
» Regulators – inverter technology
» Suppliers – Australian regulatory environment

> Adam Mackett
> 22 April 2016
3. Supply Chain 10
Local Procurement
Knowledge Gap
› Understanding of input materials and equipment
› Relationships with suppliers

› In-country supply chain facilitates project:
» Scheduling
» Cost Estimating
» Quality
› Develop/ use local procurement capability
› Commitment to local suppliers encourages
manufacturing investment and improves prices
through economies of scale, e.g. IXL (Haan
Australia) fabricated 102,000 tables at Geelong.
> Adam Mackett
> 22 April 2016
3. Supply Chain 11
Local Supply Chain
Knowledge Gap
› Compliant products not available
» Key components: e.g. modules, inverters
» Enabling components: e.g. structures, cabling
› Not made or available locally
› Imported products not always AS compliant

› Work with OEMs to localise critical equipment
› Work with local suppliers to develop products
› Develop clear specifications/ documentation

> Adam Mackett
> 22 April 2016
3. Supply Chain 12
Design
Knowledge Gap
› Applying standard designs to local conditions
› Relevant local standards

› Allow for localisation of:
» Standard designs and design improvements
» Components
» Methods
› Aspects to consider:
» Local environment
» Local transport
» Site conditions

> Adam Mackett
> 22 April 2016
4. Construction 13
Community Engagement
Knowledge Gap
› Local community concerns and expectations

› Use experienced community engagement staff
› Start early, engage regularly
› Build trust by using same staff throughout
› Co-ordinate owner and contractor efforts
› Develop a local employment participation plan
› Be aware of the impact of non-local workers
› Adapt activities to the community; interest will be
proportional to the project’s impact
› Be ready to provide controlled visits to the site

> Adam Mackett
> 22 April 2016
4. Construction 14
Structural Works
Knowledge Gap
› Internal (to site) logistics
› Most productive work methods
› Quality assurance methods

› Planning to support direct delivery of materials to
work zones – reduce internal traffic movements
› Plan and manage structural works execution to:
» Integrate with electrical works
» Reduce installation timeline
» Increase installation quality – reduce rework
» Improve teams’ skills and productivity

> Adam Mackett
> 22 April 2016
4. Construction 15
Electrical Works
Knowledge Gap
› Internal (to site) logistics
› Most productive work methods
› Quality assurance methods

› Planning to support direct delivery of materials to
work zones – reduce internal traffic movements
› Plan and manage electrical works execution to:
» Integrate with structural works
» Reduce installation timeline
» Increase installation quality – reduce rework
» Improve teams’ skills and productivity
» Reduce and manage waste
> Adam Mackett
> 22 April 2016
5. Commissioning 16
SCADA and Communications
Knowledge Gap
› Meteorological data collection and processing
› Standardised I/O list for solar plants

› Maintain consistency in SCADA system design
› Co-ordinate with all stakeholders, including:
» Owner
» Operator(s)
» NSP
» AEMO
» Carriers
» Installation and commissioning sub-contractors

> Adam Mackett
> 22 April 2016
5. Commissioning 17
Commissioning of Inverters
Knowledge Gap
› Inverter OEM knowledge of local requirements for
registration, and model accuracy and validation
› PSS/E model inputs mapped to inverter settings
› Interaction between inverter and control system

› Allow time for:
» Educating inverter OEMs
» Inverter model development by OEMs
» Inverter model validation
» Mapping model inputs to inverter settings
» Modelling inverter + controller as single system

> Adam Mackett
> 22 April 2016
5. Commissioning 18
Minimum Capacity Test
Knowledge Gap
› No industry standard for plant acceptance
› No standard test methodologies

› Agree and document at the outset the acceptance
criteria and associated test procedures
› Consider criteria that would reflect the intended AC
capacity at the Connection Point under normal
operating conditions, rather than just the inverter
nominal power at 25°C and unity power factor.

> Adam Mackett
> 22 April 2016
5. Commissioning 19
Co-ordination with NSP during Commissioning Generation
Knowledge Gap
› Lack of relevant commissioning experience:
» Many small generating modules
» Control of variable generation
› Appropriate procedures

› Actively engage with the NSP
› The commissioning plan and procedures should:
» Be started at least 3 months before commissioning
» Be developed with the NSP
» Identify all activities that involve the NSP
» Aim to schedule key dates a month in advance
» Allow for the unpredictable
> Adam Mackett
> 22 April 2016
5. Commissioning 20
Commissioning of Generating System to AEMO requirements
Knowledge Gap
› Network data in remote areas
› Inverter fault-ride-through:
» Impact poorly understood
» Characteristics poorly modelled and documented

› Measure pre-generation quality of electricity
› Know AEMO expectations before drafting GPS
› Allow extra time (3 months) to develop
commissioning and GPS compliance plans with NSP
› Review design to ensure consistency with GPS.

> Adam Mackett
> 22 April 2016
Questions 21
Thank you for your attention

> Adam Mackett
> 22 April 2016

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What challenges were faced in coordinating commissioning activities with the network service provider?

What challenges were faced in coordinating commissioning activities with the network service provider?

What knowledge gaps existed around inverter modeling and validation?

What knowledge gaps existed around inverter modeling and validation?

AGL Energy Solar

7. Publications .............................................................................. 18

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 1

Table 1 – Final Report requirements

(iv) a statement of the Funds, Recipient Refer to Section 3 – Funding Statement

(vii) copies of any published reports, promotional Refer to Section 7 – Publications

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 2

(iii) for any on-going knowledge sharing Not applicable

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 3

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 4

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 5

f) share knowledge regarding the Project in Refer to:

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 6

g) contribute to the research infrastructure being Refer to knowledge sharing report:

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 7

Table 4 – Project Funding

ARENA Project Milestones - Nyngan 116,130,000

ARENA Project Milestones - Broken Hill 40,570,000

ARENA Knowledge Sharing Milestones 10,000,000

Total Funds paid by ARENA (excluding GST) 166,700,000

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 8

Table 5 – Final Report requirements

Funds paid by ARENA 166,700,000

Recipient Contributions from AGL 194,744,830

Recipient Contributions from First Solar 10,249,728

Other Contributions from NSW State Government 64,940,000

Bank interest received net of bank fees 2,694,658

Total received 439,329,216

Broken Hill payments 152,153,877

Nyngan payments 288,433,994

Total spent 440,587,871

Total amount remaining1 -

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 9

Table 6 – Summary of Project Funding Milestones – Broken Hill

BH4 – Connection Agreement executed 31 Oct 2013 6 Dec 2013

BH7 – Site mobilisation 15 Jul 2014 26 Aug 2014

BH10 – Practical Completion of all Sections 31 Oct 2015 16 Dec 2015

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 10

NY6 – Connection Agreement executed 30 Nov 2013 27 Mar 2014

NY7 – Site mobilisation 28 Feb 2014 1 May 2014

NY10 – Practical Completion of all Sections 30 Jun 2015 29 Sep 2015

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 11

6.1. Knowledge Sharing – Engineering

2A Grid connection modelling to define solar plant performance characteristics

2B Defining communications requirements for a new generator

2C Grid connection modelling and inverter characteristics

2F Impact of temperature on plant performance and overhead line design

2G Review of connection feasibility on the UQ Gatton 3.3 MW photovoltaic array

3C Guide to engineering design and procurement

AGL Solar Project - ARENA Final Report_Rev 1_190607.docx_11.07.2019 AGL Confidential 12

6.2. Knowledge Sharing – Regulatory

2E Preparation of connection studies

4H Guide to gaining regulatory approvals for large-scale solar projects in NSW

5E AEMO Generator Registration