Multi-million overhaul at Callide Power Station gets under way

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CS Energy is carrying out a $34 million overhaul program on two generating units at Callide Power Station until late June 2022.

The overhaul program will have a peak workforce of approximately 270 people, which will include approximately 220 contractors and about 50 employees from Callide Power Station’s regular workforce.

As a major electricity provider, this vital work is part of CS Energy’s investment in its power stations to support the reliable supply of electricity to homes and businesses. It does that this by carrying out regular overhauls and maintenance of its coal-fired generating units, which play an important role in supporting security of supply, particularly during peak demand periods.

At the same time, CS Energy is creating a more flexible and diversified energy portfolio for its owners – the people of Queensland – by investing in renewable energy, hydrogen, batteries, and electric vehicle charging. 

CS Energy is delivering the Callide overhaul program with its Asset Management Alliance Partner Downer Group, and major contractors Intertek and Solaft.

One of the people who will help deliver this important program of works is Outage Coordinator Rod Callow.

Rod Callow.

Rod Callow has worked at CS Energy’s Callide Power Station for 22 years. In that time he has worked in overhauls, operations and maintenance at the power station. He was also the site supervisor of the neighbouring Callide Oxyfuel Project.

In his current role he coordinates Callide’s annual program of overhauls.

What units are being overhauled at Callide in 2022?

This year we’re overhauling Unit C3 from 26 March to 29 April followed by Unit B2 from 6 May to 17 June. There is a one-week gap between the two overhauls for people to have a break, but essentially the same workforce will carry out the two overhauls.

How far ahead do you prepare for a typical overhaul?

Generally 18 months. This is because there are long lead times for certain power generation equipment and parts. We also need to plan well in advance to line up our key overhaul contractors. For example, pressure welders are in high demand and the good ones are committed well in advance.

Describe a typical day for you working on the overhaul.

In the lead up to the overhaul I ensure that our budget and documentation are ready for the overhaul. During this phase I also spend a lot of time liaising with our key stakeholders, including major contractors and our warehouse, maintenance and operations personnel.

Once the overhaul starts, we’re in the execution phase and most of us work 12-hour shifts, six days a week. My focus is ensuring the overhaul is delivered safely, to a high standard, on budget and according to schedule. With COVID-19 we also implement additional hygiene controls to keep our people and the local community safety.

How do you achieve work-life balance during an overhaul?

For me it’s about staying connected with my family and friends. I like to drive to the coast to take my son reef fishing on the weekend, go out to dinner with friends, or just go for a drive near Biloela.

What’s the best thing about working on overhauls?

The reward of completing the overhaul and seeing the unit is back online and sending electricity to the grid.


CS Energy has comprehensive COVID-19 controls to keep its workers and local communities safe, support its customers and ensure a reliable supply of electricity. This includes mask-wearing, physical distancing, hygiene controls, and restricted access to certain areas of site for non-essential personnel.

To manage the extra workers on site for the overhauls, it is implementing additional COVID-Safe measures. These include:

  • Screening of overhaul contractors through rapid antigen testing and completion of a Health Check Declaration prior to their arrival at site for the first time.
  • Random RAT testing throughout the overhauls.
  • Limiting the number of people in workspaces, crib huts and buses to and from site
  • Increased cleaning and staggered meal breaks
  • Extra hygiene stations around site, and
  • Controls around lifts.
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