Poole Bakery Combined Heat and Power (CHP) Project

Case study 15904

Name of Client and Location: BasePower
Addo Foods Group, Poole Bakery, Poole BH15 2AS
Project Value: £119,738.15
Duration of the Project: The project started in March 2020 and despite the Coronavirus pandemic still aims to meet the following key dates; first energisation of the 1500 kVA transformer on 18 June in readiness for the G99 Testing 9 July and first generation of power to the bakery 10 July 2020. Powersystems scope on site will be completed following the energisation of the 1500 kVA transformer and hand over of the CHP Substation in June 2020.
Services: Electrical infrastructure.
Market Sector: Cogeneration
Powersystems Fact: Powersystems, your high voltage specialist partners, have connected several Combined Heat and Power (CHP) generators to the grid since 2000 on behalf of a number of different cliental. This is one of four projects completed this year for our longstanding customer BasePower

Poole Bakery Combined Heat and Power (CHP)

Powersystems high voltage (HV) power engineering were responsible for the design, installation, testing and commissioning of the electrical infrastructure associated with the construction of the 1.3 MW Combined Heat and Power (CHP) Generator Connection at Poole Bakery.

Combined Heat and Power (CHP) generation schemes allow the customer to generate their own electricity and then utilise the heat produced in this process to heat buildings and hot water systems. This not only reduces their reliance on the electricity grid, it also saves money on their electricity and gas bills whilst moving closer to a greener self-sufficient future. As an added bonus, any excess electricity generated which is not required by the factory can then be exported and sold to the grid.

The CHP plant was designed to provide Poole bakery with a more economical alternative supply of electricity as well as hot water and steam to supplement the systems already in place. The principles of this development and its impact on environmental, social and economic factors were carefully assessed before being given the go-ahead.

Poole Bakery CHP plant is a 1.3 MW generation platform that will begin to supply power to the bakery in July 2020. The site consists of one 1.3 MW generator powered by an MTU 12V4000 GS Engine supplied by 2G Ltd, which is capable of supplying electricity continuously to the bakery in parallel to the grid. As a trusted NERS accredited company with over 40 years’ experience, Powersystems were appointed to assume the responsibility for the installation of electrical infrastructure.

Project facts and figures:

  • Number of generators: 1
  • Generator capacity: 1.3 MW
  • Total installed capacity: 1.3 MW
  • Number of transformers: 1
  • Transformer rating: 1500 kVA
  • Connection Voltage: 0.415 kV
  • Altitude of site: 33 ft
  • Length of onsite 11 kV cabling: 0.08 km
  • Length of onsite 400 V cabling: 0.20 km
  • Length of onsite control and signal cabling: 0.20 km
  • Powersystems are a Lloyds registered (NERS) approved independent connection provider (ICP)

Powersystems Partnerships

The site is located in Poole, Dorset and was constructed in partnership with Njhuis Construction and 2G Ltd on behalf of the client, BasePower.

The site connects onto Addo Food Group’s 11 kV network which is a part of Scottish and Southern Energy’s (SSE) larger distribution network.

Powersystems have connected more than 20 MW of CHP generator projects to the grid over the years, this project being the fourth one this year for our client BasePower, which exemplifies our strong and trusting relationship.

Our engineers have the much-needed experience of working with every Distribution Network Operator (DNO) across the UK on this type of project, helping customers connect this type of project up and down the country.

CHP development

As UK energy production is changing fast and becoming more expensive, manufacturers who consume large amounts of energy need to find new ways to reduce cost and remain competitive.

Poole CHP will allow our client BasePower to provide the Poole bakery with on-site energy generation at a reduced cost when compared to more conventional sources. This not only helps the manufacturer reduce cost, it also addresses the Government’s strategy for a low carbon economy.

CHP technology works by utilising a fuel source to generate electricity, this project utilised a typically used fuel source in natural gas. The electricity produced by the CHP will be utilised by Poole bakery to match the current load consumption at a reduced rate.

The CHP engine will also harness the waste heat produced by the process of generating electricity, this heat will distribute hot water and steam through heating pipework to provide heating and hot water to the Poole bakery buildings.

By being able to generate electricity and heat through one fuel source simultaneously, the CHP becomes much more efficient than traditional power generation due to the reduction in wasted energy and has been known to improve energy efficiency by up to 45%.

Scope of works and major design considerations

The major items of electrical Infrastructure that Powersystems designed, supplied, installed, and commissioned were for the design, supply, installation, testing and commissioning of the 11 kV grid connection consisting of:

  • 1 x GBE 1500 kVA, 11/0.415 kV ONAN Dyn11 transformer and associated bund
  • Installation of a Schneider RN2d-T2 close-coupled Non-Extensible Ring Main Unit (RMU)
  • 11 kV cabling between the CHP Substation RMU and the existing network, including HV jointing works which required an overnight shutdown
  • 415 kV connection from the RMU to 2G’s G99 Schneider Masterpact circuit breaker
  • Installation of the Argand Monitoring and Control panel for site import/export signals to the BMS panel to enable control of the generator output (Argand Monitoring is a power measurement panel which controls the output of CHP)
  • 415 kV auxiliary supply connections from 2G’s auxiliary CB to the boiler house distribution board
  • Carry out full protection studies and upload protection settings to associated circuit breakers
  • Earthing Study and Lightning Protection Risk Assessment
  • Commissioning
  • Transformer earth system installation and testing
  • Within the CHP site, the installation of low voltage, control, signal and communications cabling works

Poole Bakery Project timings

Construction of the Poole Bakery CHP generator initially began in March 2020. Unfortunately, this was the same time the UK went into lockdown due to the Coronavirus pandemic, but despite the tighter government restrictions, and with an effective health and safety approach on site, the project was allowed to continue. Powersystems mobilised to site in May 2020 which involved preparing the ground for construction activity. Plant deliveries such as Transformer, RMU and Generator commenced June 2020, with key dates such as Energisation and G99 Testing being set for the 18th June and 9th July respectively.

What the client wanted

As UK energy production is changing fast and becoming more expensive, manufacturers who consume large amounts of energy need to find new ways to reduce cost and remain competitive.

BasePower offer a solution to manufacturers via their award-winning business model, that would see manufacturers develop and operate on-site energy generation schemes. This not only helps the manufacturer reduce cost, it also addresses the Government’s strategy for a low carbon economy. Powersystems being an Independent Connection Provider (ICP) would be charged with becoming a conduit for the grid connection to allow these types of schemes become reality.

How Powersystems helped:

Powersystems were appointed as the CHP project HV contractor, involved with the design, installation and commissioning of the electrical infrastructure for the CHP project. Powersystems aim was to provide a high-quality service throughout this project, Powersystems achieved this by setting out objectives such as ensuring technical correctness, ensuring the client was getting exactly what they asked for whilst adding cost-effectiveness and finally by adhering to the number one Powersystems moto of “Safety First”.

During the project there were a number of obstacles to overcome and Powersystems engineers were at hand to provide full support to the client through our excellent engineering knowledge and experience, which enabled the client to smoothly and successfully complete the project.

Powersystems worked closely with the project partners in order for the client to meet their deadlines that included arranged G99 testing and energisation date of 18th June and 9th July 2020. To achieve this, Powersystems engineers worked with the customer to prioritise the work tasks which resulted in the customer being able to generate power at the set target date to avoid costly penalties.

The list of responsibilities tasked to Powersystems can be summarised by the below;

  • Electrical design
  • Interface with SSE to co-ordinate an overnight shut down
  • Switchgear installation and commissioning
  • Transformer installation and commissioning
  • Design, supply and installation of cables and containment
  • HV testing
  • Senior Authorised Person (SAP) provision

Design works

Design work is a vitally import part of any Powersystems project, at this stage we ensure the project will meet the clients regulatory, economic and most importantly safety requirements. The design works included in this project are listed below;

  • 1500 kVA 11/0.415 kV Transformer bund/plinth design including general arrangements of the transformer area.
  • Transformer HV and LV earthing design – this included the general arrangements and conductor calculations for cable sizing adequate enough to carry the relevant fault currents in the event of an earth fault.
  • HV and LV cable calculations and cable sizing appropriate to the project loads.
  • HV and LV cable route design, including full site layout highlighting the fully ducted route from the existing network to the CHP Substation. This also included a trench section design which were issued to the civils for construction.
  • Fault calculations and Protection study for all new equipment, all the new equipment required protection co-ordination to achieve correct and effective grading and this was achieved through the protection study. This included producing a protection Single Line Diagram (SLD) and the study of the protection relay curves using Amtech Protect Software and CAD.
  • Control and signal cable – this included the design of all small power and equipment control wiring.

Installation works

Following the design stage, the installation work listed below was undertaken and completed;

  • Civils works – the cable route including ducting along with the transformer plinth were completed.
  • 11 kV cable installation – 2 no. of 95 mm2 triplex cables at 40 m were installed into a fully ducted route from a joint pit located close to the Bakery’s Westway Substation and arrived at the close-coupled RMU/transformer plinth located in the CHP area.
  • Transformer – Installation of the 1500kVA 11/0.415 kV Dyn11 transformer and close-coupled RMU onto the newly installed plinth located in the CHP area.
  • LV cable installation – 0.415 kV single core AWA Cu cables were installed between the ABB ACB at the transformer LV cabinet and the CHP G99 CB.
  • Small power, control and signal cables were installed for various LV equipment such as, Tariff Meters and the Argand Monitoring and Control Panels. These enabled the client to produce an accurate bill of the energy being sold to the Bakery and site load measurements/G100 trip signals respectively.
  • Earthing – this included the HV earth mat which was 25x3mm Cu tape that encompassed the transformer area. The transformer tank was earthed at two POC using 70mm2 BS6491 LSZH, along with any other extraneous metal parts such as cable glands, gland plates and the TX fencing. Powersystems also supplied a 300 mm2 LV earth to clients LV panel.
  • Argand Monitoring and Control Panel installation – the monitoring panel was installed at the Intake substation known as Millers S/S and involved terminating small power, voltage and current reference cables. This panel used the voltage and current to calculate the site load reference which was communicated to the control panel at the boiler house via a fibre optic cable. This visually showed the values on a remote display at the Intake Substation and to the client via their BMS, the control panel would also provide a G100 trip signal to the CHP generator if a load set point was exceeded by the generator.
  • HV Terminations and Joints – there were several HV terminations and joints completed during the project, such as 11 kV indoor straight terminations at the RMU SW1 and RMU SW2. Also, the 11 kV transition Joints completed at the joint pit near Westway S/S.

Commissioning works

  • Electrical Installation certificate completed on newly installed LV circuits.
  • Insulation Resistance testing of all control and signal cables.
  • Transformer and RMU cold commissioned, including ductor tests of Bus bars and disconnector switches, 5kV megger tests through the RMU and HV side of the TX and a 1kV megger test on the LV side of the TX.
  • Functional testing of all newly installed equipment, including the Schneider RMU.
  • DC pressure testing of 11 kV cables between all equipment completed using Powersystems own DC pressure test kit.

Energisation works

  • Provision of an 11 kV SAP to liaise with SSE to witness isolation and earthing of DNO CB.
  • Provision of an 11 kV SAP to take control of Addo Foods 11 kV Network and control the overnight site shutdown
  • Provision of an 11 kV SAP to attend site to provide supervision and to undertake pre-energisation checks and issue safety documents to Powersystems operatives.
  • Provision of an 11 kV SAP to carryout HV cable testing and initial energisation of the CHP CB.

The results:

The Poole Bakery CHP connection work was completed in line with the client programme against constricted timescales and within budget. The first generation to the bakery was achieved on 10th July 2020. This project is just one of four of BasePower CHP projects this year and exemplifies a long-term working partnership with Powersystems UK.

Environmental benefits

  • Due to the fact that less fuel is burned to produce a given energy output and the bakery is avoiding the use of power from the grid which mitigates transmission and distribution losses, the CHP therefore reduces emissions of greenhouse gases and other air pollutants such as carbon dioxide, nitrogen oxide and sulphur dioxide.

Economic benefits

  • The CHP will save the bakery considerable amounts of money on their energy bills due to its high efficiency.
  • Protection of revenue through onsite generation and improved reliability, the CHP can allow the bakery to continue to operate in the event of an interruption of the grid supplied electricity.
  • Less exposure to electricity rate increases, due to the fact less electricity is being purchased from the grid, the bakery will have less exposure to any rate increases.

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