Low‑voltage and HV‑interface design, installation and commissioning for on‑site industrial energy generation
Project Snapshot
| Project Detail | Information |
| Client | BasePower |
| Location | Plastic Omnium, Edison Road, Hams Hall, Birmingham, B46 1DA |
| Project Value | £165,895.80 |
| Project Duration | Sept 2020 – Jan 2021 |
| Services | LV Electrical Infrastructure, CHP Connection, Testing & Commissioning |
| Market Sector | Cogeneration / Industrial Manufacturing |
| Installed Capacity | 1.3 MW CHP |
| Connection Voltage | 400 V (LV) with interface to private 11 kV network |
| Powersystems Role | Full LV/HV design, installation, testing, commissioning & SAP provision |
| Powersystems Fact | Powersystems have connected CHP generators to the UK grid for over 20 years. This project was the third of four CHP schemes delivered for BasePower in the same year. |
Plastic Omnium Edison Road 1.3 MW CHP Case Study
Download the full Plastic Omnium Edison Road CHP Case Study — ideal for engineers, developers and technical stakeholders. This summary outlines the 400 V CHP connection, switchboard integration, LV cable installation, containment design and full G99 commissioning delivered by Powersystems for the 1.3 MW CHP system. It also highlights earthing design, fault studies and SAP‑managed energisation required to integrate a CHP plant into a busy industrial manufacturing environment.
Client & Site Background
Plastic Omnium is a global leader in automotive components and intelligent exterior systems, operating high‑energy production processes across its UK manufacturing sites. Rising energy costs and sustainability goals led the business to invest in on‑site generation as part of a wider carbon‑reduction strategy.
BasePower partnered with Powersystems to deliver a 1.3 MW CHP system providing electricity, heat and hot water to reduce operational costs and enhance resilience.
The Challenge
The client required a full LV/HV electrical connection solution to integrate a new CHP generator into an operational automotive manufacturing facility. Key challenges included:
- Installing new 400 V CHP connection within a busy industrial site
- Integrating with the factory’s private 11 kV network (via WPD)
- Delivering works during the height of COVID‑19 restrictions
- Designing cable routes that crossed HGV delivery routes and internal pipe bridges
- Implementing G99 import/export control and constraint signalling
- Completing the installation within a tight programme to meet fixed testing dates
Powersystems were appointed to design, install and commission all electrical infrastructure required to deliver the CHP platform.
Our Engineering Solution
Powersystems delivered the complete electrical infrastructure for the CHP installation, including:
- HV CT installation at the site incomer (SAP‑controlled shutdown)
- Integration of a Schneider MTZ2 2500A AIB into the existing LV switchboard
- LV containment route design and installation (160 m ladder system)
- Installation of 1.2 km of 400 V cabling via cable ladders and high‑level pipe bridges
- Control, signal and communication cabling
- 400 V auxiliary supply into pump kiosks and local distribution systems
- Installation and configuration of the Argand import/export system for generator modulation
- Full earthing upgrades and bonding works
- Protection programming, LV testing and G99 commissioning
- SAP‑managed energisation
This resulted in a fully integrated CHP solution with automated constraint control and high electrical reliability.
Project Process
- HV/LV design, protection modelling and earthing design
- Civil preparation, containment installation and route setting
- HV CT installation via SAP‑controlled shutdown
- LV cabling, containment and Argand system integration
- Functional testing, protection testing and commissioning
- SAP‑controlled energisation on 1 December 2020
- G99 testing on 18 January 2021 and first export on 19 January 2021
Project Facts & Figures
- Generator: 1 × 1.3 MW MTU 12V4000 GS CHP
- Installed Capacity: 1.3 MW
- Voltage: 400 V
- LV cabling: 1.2 km
- Control & signal cabling: 0.25 km
- Altitude: 264 ft
- Cable containment: 160 m
- NERS Accredited ICP: Yes
Technical Specifications
Major Electrical Installations
- HV CT installation
- Schneider MTZ2 2500A AIB breaker
- 400 V CHP feeder circuits
- Argand import/export monitoring panel
- LV distribution to pump kiosk
- Control and signal wiring for CHP integration
- Earthing, CPC and supplementary bonding
Design & Engineering Works
- HV CT installation design
- LV containment and route design
- LV earthing design and fault calculations
- Cable sizing and thermal modelling
- Full fault level and protection coordination study
- SLD and relay curve development via Amtech Protect
- Control & signal wiring schematics
Commissioning Activities
- LV certification
- Cable insulation resistance testing
- Functional testing of switchgear and control panels
- G100 and G99 DNO witness testing
Partnerships
Delivered in collaboration with:
- BasePower – Client
- B.T.O’Sullivan Construction Solutions – Civil partner
- 2G Energy Ltd – CHP engine supplier
- Western Power Distribution (WPD now NGED) – DNO
This was the third CHP project delivered for BasePower that year, reinforcing a long‑term partnership.
Key Risks & Mitigations
- COVID‑19 restrictions during construction – Mitigation: Enhanced protocols and safe‑working systems maintained programme delivery.
- Cable routes crossing busy factory logistics areas – Mitigation: High‑level containment installed on existing pipe bridges.
- Integration with ageing LV switchboard – Mitigation: Custom AIB breaker installation and switchboard modifications ensured safe compatibility.
- Strict G99 testing deadline – Mitigation: Prioritised work sequencing achieved energisation on 1 Dec and testing by 18 Jan.
- Limited space for cable containment – Mitigation: Bespoke containment layout designed for congested factory environment.
- Fast‑track delivery– Mitigation: Early procurement and coordinated scheduling ensured on‑time completion.
Environmental Considerations
- Enhanced energy efficiency through CHP co‑generation
- Reduced emissions of CO₂, NOₓ and SO₂
- Lower reliance on grid‑supplied electricity
- Reduced transmission losses
Economic & Social Value
- Lower energy bills through efficient on‑site generation
- Reduced exposure to grid price volatility
- Improved operational reliability
- Revenue protection via continuous operation during outages
Future Prospects
The CHP installation was delivered on time and within budget, despite COVID‑19 restrictions and complex factory routing. First export was achieved on 19 January 2021, marking successful completion of the third CHP project delivered for BasePower that year.
Related Projects
- Joseph Heler Cheese Factory CHP
- The Cornwall Bakery CHP
- Plastic Omnium Warrington CHP
Powersystems deliver LV/HV electrical infrastructure for CHP, flexible generation and industrial power projects across the UK.
Speak to our experts to support your next on‑site generation scheme.