Headworks Generator Connection Upgrade

DESCRIPTION 

The Headworks Generator Connection Upgrade (GCU) project involved the upgrade of standby power connection infrastructure across five Headworks sites throughout Auckland, supporting Watercare’s programme to improve network resilience and operational continuity. 

The project focused on enabling reliable integration of generator systems into existing electrical networks at multiple sites, each with its own constraints, interface risks, and operational requirements. 

Delivered under a design and build contract (NZS 3916), Actemium was responsible for developing and implementing site-specific solutions, ensuring each installation achieved compliance, constructability, and seamless integration with existing infrastructure. The distributed nature of the works required strong programme management, repeatable design principles, and consistent delivery across multiple live facilities. 

SCOPE 

Actemium’s scope covered the full design, coordination, and construction of generator connection upgrades across all five Headworks sites. Key activities included: 

• Development of site-specific detailed designs for generator connections, including protection, synchronisation, and control philosophies 

• Upgrade and modification of existing electrical distribution systems (LV/HV where applicable) to accommodate generator integration 

• Supply and installation of switchgear, protection relays, and synchronisation equipment 

• Installation and termination of power and control cabling for generator and associated systems 

• Integration into existing SCADA/control systems, including alarms, interlocks, and operational visibility 

• Delivery of standardised yet adaptable solutions across multiple sites to suit varying conditions and constraints 

• Implementation of temporary supplies and staged changeovers to maintain continuous operation during tie-ins 

• Testing and commissioning of generator synchronisation, load transfer, and protection systems 

• Completion of as-built documentation and O&M manuals in accordance with Watercare requirements 

As a 3916 design-build project, Actemium managed both the iterative design process and construction delivery, ensuring alignment between design intent and site execution across all locations. 

VALUE TO CLIENT 

Actemium delivered a coordinated and resilient outcome for Watercare across multiple sites, providing: 

• Strengthened Network Resilience: Reliable generator connections across five critical sites enhance system-wide response to power outages 

• Efficient Multi-Site Delivery: A structured, repeatable approach enabled consistent quality and reduced programme risk across geographically dispersed locations 

• Integrated Design and Delivery: The 3916 model ensured practical, buildable solutions with reduced interface risk and improved accountability 

• Minimal Disruption to Operations: Detailed staging and planning allowed all works to be completed while maintaining live facility operations 

• Scalable and Maintainable Solutions: Standardisation where appropriate supports long-term maintenance efficiency and future upgrades