15999 Bristol Port, Royal Portbury Dock, Ship Loader

15999 Bristol Port, Royal Portbury Dock, Ship Loader

Bristol Port, Royal Portbury Dock (RPD) Shiploader

Case study 15999

Name of Client and Location: Bristol Port, Royal Portbury Dock (RPD)
Project Value:  
Duration of the Project: 2021 (5 Months)
Services: Electrical Infrastructure as part of overall refurbishment project
Market Sector: UK Ports
Powersystems Fact: Powersystems celebrate 24 years as the UK’s first Independent Connection Provider.

Bristol Port, RPD Ship Loader

As the preferred electrical infrastructure partner for over 26 years, Powersystems one of the UK’s leading high voltage engineering specialists are delighted to have completed electrical infrastructure works for The Bristol Port Company at the Royal Portbury Dock, Grain Handling Conveyor Plant.

Bristol Port is experienced in the handling of dry bulk cargoes with an ability to handle vessels up to 130,000 dwt through their two dry bulk terminals at Royal Portbury Dock (RPD) and Avonmouth Dock

Royal Portbury Dock

The bulk terminal at RPD handles vessels up to 130,000 dwt discharging animal feeds and loading grain. RPD has the largest sea lock in the UK with dimensions of 42.7m beam x 365.7m length x 14.5m arrival draft.

There are 2 x 300m berths with four discharge units with a discharge rate of 25,000 mt / 24 hrs. In addition there is a grain loader capable of loading panamax sized vessels. Linked to the berth are two animal feed and grain warehouses with a 200,000 mt capacity and grain silos with a capacity of 15,000 mt. 

Avonmouth Dock

At Avonmouth Dock, vessels up to 40,000 dwt can be discharged and loaded. Currently they handle a wide variety of cargoes such as aggregate, animal feed, grain, wood pellets, and minerals.

They Avonmouth Dock team operate cranes from a 100mt Gottwald Harbour Mobile to hydraulic mobile cranes and have invested in over 400,000 sq. ft. of bulk warehousing at Avonmouth Dock in recent years. They also offer added value services such as blending and milling for animal feeds and grains.

Avonmouth Lock has dimensions of 30.5m beam x 266.7m length x 11m arrival draft. Avonmouth Dock is rail connected.

 

Major design considerations:

The ship loader refurbishment was ordered by the Bristol Port following a major fire.

Powersystems were engaged by Alatus as Bristol Ports preferred high voltage electrical engineering partner to deliver the HV 11 kV switchgear, transformers and 3.3 kV motor starter panels installation as part of the overall refurbishment project that Alatus has carried out for Royal Portbury Dock at the Grain Handling Conveyor Plant.

The major items of electrical plant that Powersystems designed, supplied, installed, and commissioned were:

  • To supply, deliver, offload, install, test and cold commission 3.3kv switchboard

  • To supply, deliver, offload, test and cold commission 1no 3.3/415v ANAN cast resin transformer in IP21 rated enclosure

  • To fully commission the above on site, at Bristol Port Company Royal Portbury Docks

  • To carry out 3.3kv termination works at the site

  • To provide design and engineering services, including the provision of as installed drawings upon completion, with all testing and commissioning data

  • To provide the services of a Powersystems UK Senior Authorised Person to carry out acceptance of BPC isolations and safety documents and to issue such documents to Powersystems UK competent persons under our approved safety rules and procedures

Powersystems partnerships:

Powersystems were engaged by Alatus who are crane specialists with expertise in marine, offshore, port and shipyards and construction and industrial sectors. 

Alatus expertise ensures Bristol port and terminal clients maximize their equipment’s operational efficiency. Healthier machines provide financial predictability and mitigate the risk of disruption to the port and terminal operations.

Ship Loaders have a range of specifications with varying designs and functionality. Alatus simplify  supply chain interactions by providing cross-disciplinary technical service and equipment support to keep products moving. 

They do this by delivering ad-hoc ship loader crane services, refurbishments, retrofit and upgrades, and comprehensive maintenance support contracts.

Project timings:

February – July 2021

What the client wanted:

Powersystems delivered the HV 11kV switchgear, transformers and 3.3kV motor starter panels installation as part of the overall refurbishment project that Alatus has carried out for Royal Portburty Dock at the Grain handling Conveyor Plant.

How Powersystems have helped:

Powersystems engineers were involved with the;

  • Switchgear installation and commissioning
  • Transformer installation and commissioning
  • Cable design, supply & installation
  • HV testing
  • SAP provision

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Powersystems UK Delivering Greener Power Solutions

13623 Kernow Solar Park

13623 Kernow Solar Park

Kernow Solar Park Case Study

Case study 13623

Name of Client and Location: Solar Century , Kernow Solar Park Cornwall Council
Project Value:
Duration of the Project: 2012
Services: Electrical Infrastructure, Balance of Plant
Market Sector: Solar Market Renewable Energy
Powersystems Fact: Powersystems celebrate 24 years as the UK’s first Independent Connection Provider.

Kernow Solar Park Farm

Powersystems were responsible for the design, installation, testing and commissioning of the electrical infrastructure associated with the construction of the 5 MW solar park, Kernow Solar Farm, St Mawgan near to Newquay Cornwall airport.

The Kernow Solar park scheme saw the development of a 5 MW solar park at St Mawgan, near to Newquay Cornwall airport, producing an initial income of around £700,000 per year and enough power to run 1,000 homes.

The plan for the solar park was to supply power to the national grid, but also directly to the Council owned Newquay Airport. This was to help to reduce the Airport’s carbon footprint and save money.

Both of the Point of Connections (POC) exported into the same WPD 11 kV network

Kernow Solar Park was a tangible demonstration of the Council’s tenacity and leadership. At that time, they were leading the way with their own development, showing full commitment to a Green Cornwall Strategy.

The Kernow Solar park project aimed to generate renewable electricity equivalent to almost 5 per cent of the Council’s carbon footprint.

The power supplied from the solar farm would greatly assist the Airport’s aspiration to make their operations carbon neutral, helping them to become one of the UK’s greenest airports. They were working towards certification through the Airports Council International (ACI) Carbon Accreditation Scheme and being able to source their electricity directly from the solar farm aimed to dramatically reduce their emissions.

Major design considerations:

The interconnection between the Newquay Airport 11,000v ring switchboard and the North site 1.5mw Solar Array invertor substation was made via a private wire 11,000v connection

The major items of electrical plant that Powersystems designed, supplied, installed, and commissioned were:

  • 11,000v cable pull between Newquay Airport substation and Solar Farm
  • 11,000v ring main unit and GRP substation building installation. Cable installation and terminating, earthing
  • Construct Substation Base
  • Supply, installation, testing and commissioning of Elster A1700 tariff metering
  • Extension of the Newquay Airport HV substation Airfield ring switchboard, and to provide import metering on the 11kv switchboard
  • HV Cable Trenching Works
  • Full installation test and commissioning

Project facts and figures:

  • Totalled Installed capacity: 5 MW
  • Solar farm Voltage: 11 kV
  • Connection Voltage: 11 kV
  • Length of onsite 11 kV cabling: 5 km
  • Powersystems are a Lloyds registered (NERS) approved independent connection provider (ICP)

Powersystems partnerships:

The Solar Farm was constructed by Solar Century

There is currently 1.5MW of solar PV connected between the Cornwall Airport Newquay and the solar farm via a private wire to the St Columb Major substation. This is sold to the airport at a slightly reduced rate of 15% on retail price. The private wire is rated to be able to take up to 6.7MW of capacity, and there is therefore the potential to increase the energy delivered to the Cornwall Airport Newquay.

There is also an additional southern grid connection to a second substation (St. Mawgan) which is currently where the remaining 3.5MW solar farm generation is exported to the electricity network using a separate PPA agreement

Project timings:

2012

What the client wanted:

Powersystems carried out the construction role for both the grid connection and private wire network and were appointed by Cornwall Council. Powersystems were utilised as the conduit between the client and WPD in gaining design approval for the substation, connection works and receiving WPD sign off for the build.

How Powersystems have helped:

Powersystems engineers were involved with the;

  • Interface with Western Power Distribution
  • Switchgear installation and commissioning
  • Transformer installation and commissioning
  • Cable design, supply & installation
  • HV testing
  • SAP provision

Environmental benefits

  • Renewable clean energy
  • Reduction in the Carbon Footprint of Newquay Airport

Economic benefits

  • During construction, materials sourced from local suppliers where possible
  • Local companies/resource employed where possible
  • Solar Farm could provide sufficient power for up to 1500 homes

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W13008  – Warner Bros Studios, Leavesden,  HV Infrastructure Project

W13008 – Warner Bros Studios, Leavesden, HV Infrastructure Project

Warner Bros Studios, Leavesden, HV Infrastructure Project

Case study W13008

Name of Client and Location: Warners Bros Studios, Leavesden, Hertfordshire
Project Value: 1.8 million
Duration of the Project: 13 months
Services: 33/11kv Grid connection and site wide 11kv substation infrastructure
Market Sector: Film
Powersystems Fact: Powersystems celebrate 24 years as the UK’s first Independent Connection Provider.

Warner Bros. background:

Warner Bros. Studios, Leavesden is a purpose built film production complex offering film makers and studios one of the largest and most state-of-the-art film facilities in all of Europe. It is an 80-hectare studio complex in Leavesden in Hertfordshire, in southeast England. Formerly known as Leavesden Film Studios, it is a film and media complex owned by Warner Bros. The studios were all converted from an aircraft factory and airfield called Leavesden Aerodrome, a centre of British aircraft production during World War II. It is situated in Abbots Langley, near Watford, in southwest Hertfordshire.

Warner Bros. Studios, Leavesden is one of only a few places in the UK where large-scale film productions can be made. The studios contain approximately 50,000 m2 of flexible space which includes stage space, one of the largest filtered and heated stage-based water tanks in Europe, production office space, workshops and support buildings, along with an extensive 32-hectare backlot which offers a 180-degree uninterrupted horizon, favourable for exterior sets. Following an over £110m refurbishment by Warner Bros. the studios are now one of the largest and most state-of-the-art secure filmmaking facilities in the world.

Though the studios are owned by Warner Bros., all of the studio facilities are available to rent for any production. Since acquiring the site Warner Bros. has opened a public attraction called Warner Bros. Studio Tour London – The Making of Harry Potter, which receives over 6,000 visitors a day at peak times all whilst the site maintains a secure studio space within the same complex.

The site was first built back in 1940 after the outbreak of World War II and was originally designed as an airfield.

It was not until 1997 that it was rebranded as the Leavesden Studios, A succession of major feature films made use of the site, in 1997, the first of the Star Wars prequels, The Phantom Menace and later Tim Burton’s Sleepy Hollow. By the year 2000, Heyday Films had acquired use of the site on behalf of Warner Bros. for what would be the first in a series of films, Harry Potter and the Philosopher’s Stone. Every one of the Harry Potter films was based at Leavesden Studios over the following ten years.

The site is home to the award winning Harry Potter Studio Tour, which following final completion of Harry Potter and the Deathly Hallows preserves and showcases the iconic props, costumes and film sets from all the previous productions, opened in March 2012 adjacent to the working studios the Tour offers a unique insight into the production, special effects and a backlot filled with original sets.

Project Facts and Figures:

  • 33kv Grid Route (dual 33kV supply) approx. 1.9km length in carriageway including directional drill beneath the A41 trunk road
  • Design and construction of the substation buildings and transformer compounds
  • 12.5MVA 33/11kV transformers
  • 6 panel 11kV switchboard for UKPN and customers metered supplies
  • Protection panels, battery chargers and telecontrol
  • Auxiliary pad mount 11/0.415kV transformer and grid route to UKPN 11kV network
  • All HV joints and terminations
  • Testing and commissioning of switchgear, transformers and HV cabling.
  • The site was connected to the UKPN network via dual 33kV circuits at a primary substation some 1.8kM from the site
  • In addition to the primary substation works Powersystems were also awarded the onsite private 11kV network works which involved the design and installation of 5kM 11kV cabling and 14no 5MVA 11/0.415kV transformers with close coupled RMU’s located throughout the studios complex.

Scope of works and major design considerations:

Powersystems were appointed to carry out the grid connection after a lengthy tender and negotiation process, and due to our extensive experience in completing large grid connection projects.

How Powersystems helped:

Powersystems were appointed by Ultility Partnership Limited, on behalf of Warner Bros to design, construct and commission a new Primary Substation to serve the Leavesden Studios Complex. The substation was designed and constructed under Competition in Connections within the UK Power Networks DNO area.

Whilst adhering to the OFGEM and the DNO’s requirements our professionally trained engineers liaised with UKPN to ensure that the substation design and installations would meet with the DNO’s specifications and would be adopted upon completion.

The site was connected to the UKPN network via dual 33kV circuits at a Primary Substation some 1.8kM from the site.

In addition to the Primary Substation works Powersystems were also awarded the onsite private 11kV network works which involved the design and installation of 4kM 11kV cabling and 14no 1.5MVA 11/0.415kV transformers with close coupled RMU’s located throughout the studios complex.

Together with our supply chain partners, Powersystems UK were able to design, install and commission the following:

Design Works

  • 33,000/11,000v transformers – the installation, testing and commissioning of 2no 7.0/15MVA, 3ph, 50 Hertz 33/11.5kV, oil immersed, naturally cooled transformers
  • NEX – the installation of 2 no neutral earthing reactors, which were all tested upon being installed. These will be star point connected to the customer’s 33/11kV transformers
  • 11,000v Hawker Siddeley ECLIPSE indoor metal-clad switchgear –
  • 33kV/11kV cabling- install, terminate and pressure 2 circuits of 33,000v
  • Transformer protection panels – provided all 33, 000v transformer and 11,000v switchgear protection panels.
  • Battery chargers

Installation Works

  • Installation of 2 No 33Kv Circuits
  • The installation of 2 No Pilot Cables
  • 0/15mva 33,000/11,000v transformers
  • Tap change panels
  • Transformer protection panels
  • 11,000v incoming 5 panels fixed pattern vacuum circuit breaker switchboard to include all protection, marshalling panels, jointing, termination works, testing and commissioning

Commissioning Works

Commissioning of the connection was completed to estimated timescales, with on-site witness testing completed in February 2012

What The Client Wanted

Warner Bros needed absolute surety the project could be delivered within an extremely tight timescale, as the on-site construction had already commenced in readiness for the VIP and Public openings scheduled for March 2012

Following a meeting with Warner Bros UK, Hoare Lea and Utility Partnership in London, Powersystems were awarded the contract in July 2010

Project Timings

The project began in September 2010 and was completed in October 2011 

Powersystems Partnerships:

The electrical work was undertaken in partnership with Ulility Partnership Limited on behalf of the client, Warner Brothers.

The results: 

A successful delivery of a project, within budget, timescales and to the customers satisfaction.

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Powersystems UK Delivering Greener Power Solutions

15960 – Lower Dunton Flexible Generation 11 kV Substation

15960 – Lower Dunton Flexible Generation 11 kV Substation

Lower Dunton Flexible Generation 11 kV Substation

Case study 15960

Name of Client and Location: CONRAD ENERGY LTD
Lower Dunton Flexible Generation
Lower Dunton Road
Lower Dunton
RM14 3TD
Project Value: £318,896.65
Duration of the Project: December 2020 – April 2021
Services: Electrical BoP
Market Sector: Flexible Generation
Powersystems Fact: Powersystems your high voltage specialist partners have connected numerous flexible generators to the grid since 2000 and for a number of different cliental. This project is the third project undertaken tis year in what is a fairly new but exciting relationship being formed between Powersystems and Conrad Energy.

Lower Dunton Flexible Generation Substation & BoP

Powersystems high voltage (HV) electrical engineering was responsible for the design, installation, testing and commissioning of the electrical infrastructure associated with the construction of the 7.5 MW Flexible Generation Connection at Lower Dunton Flexible Generation site on Lower Dunton Road in Basildon Essex.

The plant was designed to provide flexible generation to the grid when the more conventional but unpredictable renewable energy source are unavailable. The principle of the development and its impact on environmental, social and economic factors was carefully assessed and given the go-ahead.

Lower Dunton Flexible Generation site is a 7.5 MW generation platform that will be available to export energy to the grid early April 2021. The site consists of three 2.5 MW generators powered by an MTU GS Engine supplied by VPower Ltd, which is capable of supplying electricity to the grid when called upon. 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: 3
  • Generator capacity: 2.5 MW
  • Total Installed capacity: 7.5 MW
  • Connection Voltage: 11 kV
  • Altitudes of site: 105 ft
  • Length of onsite 11 kV cabling: 0.15 km
  • Length of onsite 400 V cabling: 0.2 km
  • Length of onsite control & signal cabling: 1.0 km
  • Powersystems are a Lloyds registered (NERS) approved independent connection provider (ICP)

 

Powersystems partnerships

The site is located on Lower Dunton Road, Lower Dunton in Basildon and was constructed in partnership with ANTS Civil Engineering Ltd on behalf of the client, Conrad Energy Ltd.

The site connects onto the UK Power Networks (UKPN) 11 kV network. Powersystems have connected countless Flexible Generation and STOR projects to the grid over the years, this project being one of three projects undertaken this financial year for our client Conrad Energy, which is a young but exiting relationship being built. 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.

 

Flexible Generation development

As the UK energy production is changing by becoming greener and relying more on renewable energy to become net zero by 2050, flexible generation sites will help fill the gap when the more unpredictable wind and solar energy sources are unavailable.

The Flexible Generation 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 Generators will be utilised by the grid in times of demand when renewable energy is unavailable.

 

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:

  • Design and construction of the 11 kV GRP substation
  • Installation of the five panel 11 kV Schneider Genie Evo Switch Board
  • Installation of the 500 kVA Auxiliary transformer
  • Installation of the 300 mm2 11 kV incomer circuit and 185mm2 11 kV Triplex generator and Auxiliary Transformer circuits
  • Earthing installation works
  • Installation of low voltage, control, signal and communications cabling works
  • Design installation of the LV infrastructure
  • Design and installation of the compound lighting and control panels
  • Carry out Fault level and protection co-ordination studies

 

Project timings

Construction of the Lower Dunton site initially began in December 2020. Unfortunately, this was during a critical stage of the UK lock down due to the Coronavirus Pandemic, but despite the necessary restrictions and with the right health and safety approach and procedures implemented, the project continued at a steady and efficient pace. Powersystems mobilised on site in December 2020 which involved preparing the ground for construction activity. Plant and material deliveries, with key dates such as Energisation and G99 Testing on 18 March 2021 and 7 April respectively.

 

What the client wanted

Climate change is the biggest challenge of our time, so the energy landscape is rapidly evolving. The UK’s power network requires smart solutions to keep the lights on.

Conrad Energy’s growing generation portfolio provides power to over a million homes within the UK when the more unpredictable wind and solar assets are unavailable, hence the need for the flexible generation sites

Conrad Energy are driven by positively impacting the climate change, they offer services to support the delivery of power solutions to commercial and industrial business including the national grid to help achieve the UK’s energy transition to net zero by 2050.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 have helped

Powersystems were appointed as the Balance of Plant HV contractor for the project, involved with the design, installation and commissioning of the electrical infrastructure for the generation 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 challenges that presented themselves and Powersystems engineers were at hand to provide full support to the client to help overcome any challenges 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. 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 and studies
  • Interface with UKPN to co-ordinate any DNO requirements
  • Control Panel installation and commissioning
  • HV and LV infrastructure installation and commissioning
  • Cables & containment design, supply & installation
  • HV/LV 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;

  • Design of the GRP Substation.
  • Battery Charger Unit design.
  • Civil designs for the GRP Substation and Auxiliary transformer.
  • Design of the clients HV network.
  • Design of the LV network
  • HV/LV cable calculations and cable sizing appropriate to the project loads.
  • Fault level Study and full report.
  • Protection co-ordination and full report.
  • Control & 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;

  • Installation of earthing systems.
  • Installation of the GRP Substation
  • Installation of HV cables.
  • Installation of LV and control cables.
  • Installation of the 500 kVA Auxiliary transformer.
  • Installation of the five panel 11 kV Schneider Genie Evo SWB
  • Installation of the 110 V DC Battery charger unit.
  • Installation of the compound lighting including bespoke lighting contactor panel.
  • Installation of the oil tank control panels.

Commissioning works

  • Hot and Cold commissioning o f the 11 kV SWB.
  • Hot and Cold commissioning of the 500 kVA TX.
  • AC Pressure testing of newly installed HV cables.
  • Electrical Installation certificate completed on newly installed LV circuits.
  • Insulation Resistance testing of all control and signal cables.
  • Functional testing of all newly installed equipment.

Energisation works

  • Provision of an 11 kV SAP to take control of the client’s 11 kV Network
  • 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.

The results

The Lower Dunton BoP contract work was completed in line with the client programme against constricted timescales and within budget. This project is the first to be completed by Powersystems for our new client but hopefully not the last as we hope to build a strong and supporting partnership between Powersystems UK and Conrad Energy as we work towards our common goal of making the UK greener.

 

Environmental benefits

  • Due to the more conventional renewable sources of energy such as Wind and Solar being unpredictable the grid will still require other forms of generation to sustain a stable grid. Natural gas generation can provide this flexible generation and at a 50-60 percent less CO2 emissions when compared to the conventional coal or oil type generation.

Economic benefits

  • The Site will provide grid stability and help support the local grid providing energy to numerous homes in the area.

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Powersystems UK Delivering Greener Power Solutions