Case Studies

High-Reliability 24V DC Power System for Critical Airport Infrastructure

Major airport environments demand absolute reliability, regulatory compliance and long-duration backup performance from their DC power systems. This project showcases how an Australian-engineered Intelepower 24V DC power system was supplied to meet the performance, compliance and reliability requirements of a major airport environment.

Project Overview

As part of Melbourne Airport’s Gas Emission Reduction Program, critical substation DC power upgrades were required to support essential services including:

• Runway and terminal emergency lighting
• Air traffic control systems
• Emergency communications networks

The system needed to deliver up to eight hours of standby backup, comply with Australian Standards, and be delivered within a compressed project schedule. The EPC selected Intelepower following prior successful maintenance and rectifier repair works on an existing third-party DC system onsite.

The expansion of the airport’s terminal facilities required a robust energy backbone to ensure zero downtime for security and navigation systems. Central to this project was a high-capacity DC Power System designed to handle fluctuating loads while maintaining extreme thermal stability. By implementing a redundant architecture, the airport can maintain full operational capacity even during primary grid failures.

The Intelepower Solution

An Australian-engineered Intelepower 24V DC power system was supplied to meet the performance, compliance and reliability requirements of a major airport environment. The system underwent eight-hour discharge testing under controlled load conditions and was fully commissioned in accordance with Intelepower procedures and applicable Australian regulatory requirements.

Working within an active international airport presents unique logistical challenges, requiring strict adherence to safety and security protocols. Our team managed the end-to-end DC Power System Installation, ensuring that new rectifiers and battery strings were integrated without disrupting existing services. This precision-led approach is vital for critical infrastructure where there is no margin for error during the commissioning phase.

Key system features included:

• Dual X and Y DC architecture for redundancy and fault tolerance
• Yuasa FXH100 VRLA batteries selected for long design life and dependable backup performance
• Single-cabinet configuration with natural ventilation for substation environments
• The Intelepower DC power system was designed and manufactured at the Carole Park production facility
• Full discharge testing and commissioning in accordance with Australian regulatory requirements

This approach ensured the system met both operational resilience and long-term serviceability requirements expected in a safety-critical airport environment.

Performance Outcomes

The Intelepower DC power system was delivered and commissioned on schedule, meeting all performance, safety and compliance requirements.

Project outcomes included:

• Regulatory compliance with Australian Standards and project specifications
• Dependable eight-hour backup for critical infrastructure
• High reliability: Yuasa FXH100 VRLA batteries provide dependable eight-hour backup for critical infrastructure
• Redundant DC architecture ensuring continuity of protection, control and communications
• Australian-engineered solution: Local engineering enabled greater control over configuration, testing and lifecycle support
• Sustainability support: Improved system efficiency contributes to reduced emissions and long-term asset performance
  
  The success of the Melbourne Airport project highlights the importance of matching advanced hardware with strategic service. To ensure long-term reliability, we recommend regular Electrical Assets Audit Services to identify potential points of failure before they impact operations.

The successful delivery reinforced confidence in Century Yuasa Batteries’ technical capability and supported further engagement, including future substation upgrades and replacement of high-maintenance NiCd systems with Yuasa VRLA technologies.

Why This Matters for Critical Infrastructure

Airports, utilities, transport networks and industrial facilities rely on robust DC battery systems to maintain protection, control and emergency systems during power loss events. This project demonstrates how engineered DC power solutions, high-quality VRLA battery systems, and proven testing procedures combine to deliver dependable performance where failure is not an option.