Steel Fabrication & Construction
Services For Power Stations
Throughout our 49 year history, we have completed numerous power station shutdowns, upgrades, asset inspections and life extensions. We collaborate with teams to build, own, and operate assets for projects and community requirements. Structural, mechanical, piping, construction of power generation assets including, gas, hydro, HFO, conventional fuel oil, biomass, and coal-fired generation units.
Since the 1980s, Sun Engineering has been involved in construction and manufacturing for the renewable energy sector, with experience in hydro, pumped storage, and solar.
We have the expertise in-house to deliver successful project outcomes. With the increase of wind farms being built in Australia, we are gearing up our workshop to support projects in Australia and beyond.
Gas Fired Power Stations
Sun Engineering has been delivering specialised construction services on gas-fired power stations for over 20 years. During this time, we have delivered combined cycle gas turbine stations (CCGT), simple cycle gas-turbine (OCGT), and reciprocating engines for several clients in Australia and the Pacific Islands region.
We understand the complex nature and precision elements required to construct a power station to reach its designed output. For this reason, we have continued to be a trusted construction partner of gas-fired power plants.
Coal Fired Power Stations
Sun Engineering founder Patrick McMonagle was seconded to Australia to build Australia’s first pulverized coal-fired power station in the 1960s. It was off the back of this project that Sun Engineering was formed in 1974.
During this time, we have delivered construction and specialized fabrication services to the majority of the coal-fired power stations in QLD, including superheater replacements, stack replacements, bag filters, steam piping, boiler support, ash water pumping, overland conveyors, dump stations, and ball mill overhauls at Swanbank, Millmerran, Bulimba, Callide, and Stanwell power stations.
Power Generation Services
Steel fabrication services are a crucial aspect of the Power Generation industry. Carbon steel is the most commonly used material due to its strength and durability, making it ideal for heavy-duty equipment such as boilers, turbines, and generators. Stainless steel is also widely used in the industry for its resistance to corrosion and heat, which is especially important in applications involving steam and other hot fluids.
Additionally, aluminium is a lightweight and corrosion-resistant material that is commonly used in power transmission systems and other equipment where weight is a concern. In all cases, the fabrication of these materials requires skilled technicians who can produce high-quality components that meet the industry’s rigorous standards for safety and reliability.
On-site welding services play a crucial role in the Power Generation industry. These services involve skilled technicians who are equipped to perform welding repairs and installations on-site, which is often necessary due to the size and complexity of power generation equipment. These services can include welding of structural components such as pipelines, tanks, and pressure vessels, as well as the repair of worn or damaged equipment.
Site welding services require specialised equipment and personnel who are experienced in working in challenging environments such as power plants. In addition to repair and maintenance work, on-site welding services are also used for the installation of new equipment and upgrades, ensuring that power generation facilities are always operating at peak efficiency and safety.
Pipe spooling services involve the prefabrication of piping systems off-site, with the resulting spools being transported and installed on-site. Pipe spooling services are particularly useful for complex projects where the construction of the piping system on-site would be impractical or time-consuming. The prefabrication process allows for faster installation times and minimizes disruption to the existing facilities. Pipe spooling services can also be used for the repair and replacement of damaged or outdated piping systems, providing an efficient and cost-effective solution for maintenance and upgrades. The use of pipe spooling services requires skilled technicians who are experienced in working with a variety of piping materials, including carbon steel, stainless steel, and other specialized alloys.
SMP (Structural, Mechanical, Piping) Construction services are a critical component of the Power Generation industry. These services encompass the construction, maintenance, and repair of the structural, mechanical, and piping systems that are integral to power generation facilities. SMP construction services cover a wide range of activities, from the installation of new equipment and systems to the repair and maintenance of existing infrastructure.
This can include the construction of power plant buildings, the installation of turbines and generators, and the maintenance and repair of piping systems, pumps, and valves. SMP construction services require skilled technicians with expertise in construction and maintenance activities, as well as a deep understanding of the complex systems and equipment involved in power generation facilities.
Our conveyor services involve the installation, maintenance, and repair of conveyor systems, which are responsible for transporting coal, biomass, and other materials to the power plant for processing. Conveyor systems are also used to transport ash and other waste products away from the power plant for disposal. Conveyor services require specialised expertise in conveyor technology, as well as a deep understanding of the power generation process.
This includes knowledge of the types of materials being transported, the required capacities of the conveyor systems, and the need for reliable and efficient operations. Conveyor services can be utilized for the installation of new conveyor systems, as well as the maintenance and repair of existing systems to ensure they are operating at optimal efficiency and safety levels. By utilizing conveyor services, power generation facilities can ensure that their conveyor systems are built, maintained, and operated to the highest standards of safety, reliability, and efficiency.
Tank fabrication services are a critical component of the Power Generation industry, as they provide storage solutions for fuels, chemicals, and other materials used in power generation processes. These services involve the fabrication, installation, and maintenance of various types of tanks, including fuel storage tanks, chemical storage tanks, and water storage tanks. Tank fabrication services require specialized expertise in tank design, fabrication, and installation, as well as a deep understanding of the power generation process. This includes knowledge of the types of materials being stored, the required capacities of the tanks, and the need for safe and reliable operations.
Tank fabrication services can be utilised for the installation of new tanks, as well as the maintenance and repair of existing tanks to ensure they are operating at optimal efficiency and safety levels.
Greenfield and Brownfield project management services are crucial for the successful execution of construction projects in the Power Generation industry. These services involve overseeing the planning, design, construction, commissioning, and maintenance of new or existing power generation facilities. Greenfield projects refer to the construction of new facilities from scratch, while Brownfield projects involve the expansion, renovation, or upgrade of existing facilities.
Project management services require a deep understanding of the power generation process, including knowledge of the various types of power generation technologies, fuel sources, and environmental regulations. They also require expertise in project management principles, including project planning, scheduling, risk management, and stakeholder engagement. By utilising Sun Engineering’s project management services, power generation facilities can ensure that their projects are executed on time, within budget, and to the highest standards of safety and quality. This can lead to increased operational efficiency, reliability, and profitability for the power generation facility.