Joseph Heler Cheese Factory – 1.0 MW CHP Electrical Infrastructure Project High-voltage design, installation and commissioning for on-site generation and energy efficiency
Project Snapshot
| Project Detail | Information |
| Client | BasePower |
| Location | Laurels Farm, Joseph Heler Cheese Factory, Nantwich, CW5 7PE |
| Project Value | £149,203.15 |
| Project Duration | Oct 2020 – Feb 2021 (Energisation: 1 Feb • G99 Testing: 12 Feb) |
| Services | 11 kV Electrical Infrastructure, CHP Grid Connection, HV/LV Installation & Commissioning |
| Market Sector | Cogeneration / Industrial Manufacturing |
| Installed Capacity | 1.0 MW CHP |
| Connection Voltage | 11 kV |
| Powersystems Role | HV design, installation, testing, commissioning and DNO interface management |
| Powersystems Fact | Powersystems have connected 22 plus of CHP generators to the UK grid since 2000 — this project marked the fourth CHP scheme completed for BasePower in that financial year. |
Joseph Heler Cheese Factory 1.0 MW CHP Case Study
Download the full Joseph Heler Cheese Factory CHP Case Study — ideal for engineers, developers and technical stakeholders. This summary outlines the 11 kV grid connection, transformer and HV CT installation, protection design, cabling works and G99 commissioning delivered by Powersystems for the 1 MW CHP generator. The full document provides technical insight into the design methodology, civil works, HV earthing and control systems required to integrate a new CHP system into a live manufacturing environment.
Client & Site Background
Joseph Heler is one of the UK’s largest independent cheese producers, supplying supermarkets, wholesalers and food manufacturers nationwide. The company operates an energy‑intensive manufacturing process requiring consistent power, heat and steam.
To improve energy efficiency and reduce operational costs, BasePower and Joseph Heler partnered to deliver a 1.0 MW Combined Heat and Power (CHP) system designed to provide reliable, low‑carbon on‑site energy generation.
The Challenge
The client required a complete HV electrical solution to integrate a new CHP system into an existing private 11 kV network supplied by Scottish Power Energy Networks (SPEN). Key challenges included:
- Connecting a new CHP generator into a live food‑production environment
- Undertaking works during strict national COVID‑19 restrictions
- Coordinating controlled shutdowns with SPEN
- Designing and installing new trench routes across busy factory access roads
- Implementing G99 import/export control and protection systems
- Delivering under tight programme deadlines to avoid generation penalties
Powersystems were appointed to design, install and commission all electrical systems to bring the CHP generator into operation.
Our Engineering Solution
Powersystems delivered the full CHP electrical infrastructure, including:
- Installation of HV CTs at the site incomer cable box
- HV containment design and installation
- Civil works including trenching, ducting and ground reinstatement
- SPEN cable joint bays and installation of new 11 kV network cables
- Installation of 95 mm² 3‑core CHP feeder cable and 185 mm² Triplex site incomer cable
- Full LV, control, signal and communications cabling
- Earthing design and installation
- Argand power measurement system enabling generator modulation and G99 constraint control
- HV testing, functional testing and G99 commissioning
The CHP generates electricity and heat simultaneously, providing a highly efficient on‑site energy source.
Project Process
- HV design, CT specification, trench design and earthing calculations
- Civil works and duct installation across factory yard
- Installation of cable containment systems and HV CTs
- Delivery and installation of HV and LV cabling
- Installation of Argand control and import/export panel
- Extensive HV/LV testing, insulation checks and functional commissioning
- SAP‑controlled energisation on 1 February 2021
- G99 testing on 12 February 2021, with first generation immediately following
Project Facts & Figures
- Generator: 1 × 1.0 MW MTU 8V4000 GS engine (supplied by 2G Ltd)
- Connection Voltage: 11 kV
- Installed Capacity: 1.0 MW
- 11 kV cabling: 0.21 km
- 400 V cabling: 0.1 km
- Control & signal cabling: 0.3 km
- Cable containment: 120 m
- Altitude: 229 ft
- NERS Accredited ICP: Yes
Technical Specifications
Major Electrical Installations
- Installation of HV CTs and new 11 kV incomer
- SPEN network cable installation and joint bay construction
- 95 mm² CHP feeder cable and 185 mm² Triplex incomer
- Argand measurement and constraint panel
- LV distribution, communication and control cabling
- Earthing system and bonding
Design & Engineering Works
- HV CT design
- HV cable and containment design
- HV/LV cable sizing and protection coordination
- HV earthing calculations and layout
- Lightning risk assessment and technical report
- Control and signal wiring diagrams
Commissioning Activities
- HV cable pressure testing
- LV installation certification
- Insulation resistance testing
- Functional testing of LV and control equipment
- SAP‑managed energisation
- G99 relay testing and validation
Partnerships
The CHP installation was delivered in collaboration with:
- BasePower – Client
- C.P.M Civil Engineering – Civil works partner
- 2G Energy Ltd – CHP engine supplier
- SPEN – Network operator
This project was the final of four CHP schemes delivered for BasePower in the same financial year.
Key Risks & Mitigations
- COVID‑19 restrictions during construction – Mitigation: Enhanced site protocols ensured safe, continuous progress.
- Complex trunking across busy access roads – Mitigation: Phased trenching minimised disruption to factory operations.
- Integration with private 11 kV SPEN‑connected network – Mitigation: Controlled shutdowns and SAP oversight ensured safe switching.
- Tight programme deadlines for G99 tests – Mitigation: Prioritised task sequencing enabled on‑time energisation.
- Space‑restricted factory environment – Mitigation: Detailed containment and cable routing avoided clashes with production areas.
- Load‑matching and export constraints – Mitigation: Argand import/export system provided precise generator control.
Environmental Impact
- Reduced carbon emissions and air pollutants
- Lower grid electricity consumption
- Reduced transmission and distribution losses
- Improved factory energy efficiency and sustainability
Economic & Operational Benefits
- Lower energy costs through on‑site generation
- Greater resilience against energy price volatility
- Reduced exposure to grid interruptions
- Improved operational reliability for manufacturing processes
Future Prospects
The Joseph Heler Cheese Factory CHP project was delivered on time and within budget, achieving energisation on 1 February 2021 and G99 approval on 12 February 2021. The generator now delivers reliable, efficient on‑site power and heat in support of the factory’s operational and sustainability goals.
Related Projects
- Cornwall Bakery CHP
- Plastic Omnium
Powersystems deliver high voltage CHP and on site generation solutions for industrial manufacturing across the UK.
Contact our engineering team to support your next energy efficiency or grid connection project.