Case Studies

Client: UGL

Location: Sydney, NSW

Completion: 2025

System Supplied: 83 x Custom Engineered Solar Battery Systems

Discover

Sydney Metro is developing Australia’s most advanced rail system, featuring fully automated, driverless trains. A critical aspect of the Sydney Metro project is ensuring the safety of passengers and the public around these new automated rail services.

To engineer the necessary safety controls for the Southwest Rail project, UGL was contracted to deliver the Corridor Intrusion Detection System and Object Detection Systems (CIDS and ODS). These intelligent systems include CCTV cameras and radio equipment programmed to detect any intrusion into the rail corridor and immediately transmit warnings to the control operators.

Maintaining a consistent, reliable power supply for this critical equipment was a key consideration, so UGL engaged Valen to custom design a turnkey power solution.

With 83 sites to fitout, it was essential for the system to be standardised and easily deployable to meet the project timeline. Valen’s experience in designing bespoke solutions, and agility in handling complex project rollout schedules meant we were well placed to co-create a solution for this critical safety system.

Design

Valen initially designed a fixed-frame solar-powered battery system that met the scope of works, however the UGL engineering team suggested several changes with the intention of simplifying the system. Our co-creation process is designed to provide plenty of space for iteration and change in the design process, with the client heavily involved at each stage.

After several discussions with the engineering and project teams, a design resembling the original concept was agreed upon and the Valen team got to work on the system’s foundations to ensure each unit could be quickly and easily deployed on site. This included some creative additions such as a ‘top cap’ design which allowed the UGL team to pour a shallow foundation that would not interfere with services.

Other convenient additions included a DIN rail at the rear of each cabinet to fit UGL’s network switch, and supplying half of the units with a 5 metre mid-hinged pole to which UGL could mount their CCTV cameras.

The final bespoke system design featured a bank of 800Ah ENLiFEN lithium batteries, selected for their compact size, enhanced capacity and excellent reliability. This system met the client’s specifications and also delivered reduced maintenance requirements thanks to the long design life of lithium batteries and their better round-trip efficiency when compared to lead acid batteries.

Deliver

Whilst the UGL team handled installation on site, Valen set the project up for a successful rollout by staging the delivery of the 83 units in three phases. The initial trial unit was fast-tracked to ensure UGL’s testing could begin on schedule. The remaining units were then manufactured in two lots so that UGL could batch their installations. And, by holding stock in our warehouse and scheduling on-demand delivery to UGL, we were able to eliminate any storage costs for UGL.

In just 12 weeks, the Valen team took UGL’s scope of works from concept to completion, designing and manufacturing a modular lithium battery system with a solar frame and 440W solar panel. Each 19RU outdoor cabinet is secure and weatherproof, protecting the 800Ah ENLiFEN lithium batteries All Factory Acceptance Testing was handled by Valen and packages arrived on site with all components ready to install. 

Support

By partnering with Valen as a single vendor, UGL was able to avoid prolonged project schedules and streamline their project with an efficient and safe rollout. Future maintenance, spare parts and support are also made easier with Valen, thanks to our focus on the complete product lifecycle and our long-term, partnership approach.

After engineering this bespoke, full turn-key solution for Sydney Metro, the Valen team identified a range of other applications where a compact, remote, solar battery system would excel. Labelled the ModX1, this modular system is now readily available for use in challenging applications where remote locations and extreme temperatures require a reliable, maintenance-free solution.

Technical Specifications

83 x Custom designed ModX1 fixed-frame solar packages, including: 

• Solar Frame and 440W solar panel
• 19RU Outdoor cabinet
• 800Ah ENLiFEN Lithium Batteries
• Half of the 83 units were supplied with a 5m mid-hinged pole for mounting CCTV cameras