Magellan Power Extends Battery Charger Life at Major Power Station
- ClientPower Station
- Date2024
- Industry SectorsEnergy Generation
- LocationAustralia
As critical infrastructure ages, preventative maintenance becomes essential to avoid costly failures. At one of Australia’s largest power stations, Magellan Power was engaged to extend the operational life of three high-capacity DC battery chargers that had been in continuous service for more than two decades. By replacing degraded electrolytic capacitors and restoring stable performance, Magellan Power helped the facility secure reliable backup power, reduce operational risks and add an estimated 10–15 years of service life to the equipment.
Solutions
Magellan Power’s service team proposed and executed a proactive capacitor replacement campaign across all three SAFT chargers.
The work scope included:
- Replacement of all high-voltage and high-ripple capacitors
- Preassembled capacitor banks with customised bus bars to simplify installation
- Verification of filter and smoothing capacitor performance
- Cleaning and inspection of PCBs and power modules
- Full functional tests post-replacement
All work was carried out onsite during a planned maintenance window, minimising disruption to operations.
Client Requirement
A major Australian power station engaged Magellan Power to assess their aging battery charger systems. These chargers, rated at 24VDC 1000A, 220VDC 400A and 220VDC 100A, had been in continuous operation for over 20 years and were vital for reliable backup and control power within the facility.
Our inspection revealed that the electrolytic capacitors, original components in all three chargers, had exceeded their expected service life, posing a significant operational risk.
RESULTS
The capacitor replacement project restored stable performance to the chargers, extended their service life by an estimated 10–15 years and avoided the cost and disruption of full system replacements.
By preventing unexpected failures and reducing ripple, the upgrade safeguarded both battery health and critical plant operations, delivering measurable cost savings and risk reduction for the client.
This case demonstrates the value of Magellan Power’s preventative maintenance services. From condition assessments through to component replacement, testing and long-term service planning, we help facilities extend the life of legacy assets, ensure operational reliability and maintain compliance in mission-critical environments. For operators of aging DC charger systems, Magellan Power provides tailored service programs that mitigate risk, reduce whole-of-life costs, and ensure backup power is always secure.
