Delivering full 132/33 kV electrical infrastructure for one of the UK’s largest onshore wind clusters
Project Snapshot
| Client | Fred Olsen Renewables |
| Location | Crystal Rig IV Wind Farm, Innerwick, Dunbar, EH42 1SH |
| Project Value | £4.4 million |
| Project Duration | Jul 2024 – Nov 2025 |
| Market Sector | Onshore Wind |
| Services Delivered | Full Electrical Balance of Plant (EBoP) |
| Powersystems Fact | Powersystems has connected over 24% of all UK wind farms — Crystal Rig IV is another successful collaboration with R.J. McLeod and Fred Olsen Renewables. |
Crystal Rig IV 49.1 MW Wind Farm Case Study
Download the full Crystal Rig IV Wind Farm Case Study to explore how Powersystems delivered the complete 132/33 kV Electrical Balance of Plant for this 49.1 MW extension to one of the UK’s largest onshore wind farms. The PDF provides a clear overview of our substation, cabling, protection and SCADA works, including 20 km of 33 kV circuits and full integration with the existing SPT transmission network. Ideal for engineers, developers and stakeholders seeking deeper technical insight into a complex wind farm expansion that now delivers clean energy to more than 50,000 homes.
Client & Site Background
Crystal Rig IV forms the latest phase in the ongoing expansion of the Crystal Rig wind cluster — one of the UK’s largest onshore wind farms. Situated in Innerwick, East Lothian, this 49.1 MW extension integrates seamlessly with the existing Crystal Rig II infrastructure and the nearby SPT 132 kV transmission network.
Owned and operated by Fred Olsen Renewables, the extension consists of 11 turbines (nine at 4.5 MW and two at 4.3 MW), supplying enough clean renewable energy to power more than 50,000 homes. Powersystems was appointed as the project’s Electrical Balance of Plant contractor, responsible for full HV and LV delivery, testing and energisation.
The Challenge
Crystal Rig IV required Powersystems to:
- Deliver a complete 132/33 kV electrical system for a major wind farm extension
- Integrate new assets with the existing Crystal Rig II substation and SPT 132 kV network
- Install 20 km of 33 kV cabling across varied terrain
- Meet tight energisation deadlines, including enabling early generation
- Maintain the highest SHEQ standards in an active multi‑contractor environment
- Engineer a system that supports long‑term renewable generation targets
Our Engineering Solution
Powersystems delivered a full turnkey EBoP package, including all HV, LV, protection, SCADA and commissioning activities.
132 kV Substation Infrastructure
- 90 MVA, 33/132 kV grid transformer
- 145 kV Hybrid (Hypact) circuit breaker with VT
- 132 kV busbars and steel support structures
- Disconnectors, earth switches and associated HV apparatus
- 33/0.415 kV auxiliary earthing transformer
33 kV Wind Farm Electrical Systems
- 5‑panel Schneider WS 33 kV switchboard
- 20 km of 33 kV cabling, jointing and terminations
- Substation and WTG earthing systems
- LV, control, communications and signal cabling
- Full LV distribution and auxiliary systems
- Compound lighting and custom control panels
- SCADA system integration with turbine OEM and client networks
- 132/33 kV protection scheme design and commissioning
Project Process
- Early 2023 — Civil works by R.J. McLeod begin
- Jul 2024 — Powersystems mobilises to site
- 2024 — Substation build, 33 kV cable installation, protection and LV systems installation
- 1 September 2025 — First energisation of substation and initial WTG array
- Autumn 2025 — SCADA integration, protection scheme finalisation and full array testing
- Nov 2025 — Full site energisation and handover
Project Facts & Figures
- 11 turbines (9 × 4.5 MW, 2 × 4.3 MW)
- 49.1 MW installed capacity
- 1 × 90 MVA grid transformer
- 20 km 33 kV cabling installed
- 5‑panel Schneider WS switchboard
- 132 kV Hybrid (Hypact) circuit breaker
- Approx. 50,000 homes powered
- Full NERS‑accredited ICP involvement
Technical Specifications
High‑Voltage (132 kV) System
- 90 MVA 33/132 kV transformer
- 145 kV Hybrid circuit breaker with VT
- Disconnectors, earthing switches, busbar supports
- Full compound earthing and bonding
33 kV System
- Five‑panel Schneider WS switchboard
- 20 km of 33 kV cable across three WTG arrays
- Turbine and substation earthing systems
- 132/33 kV protection coordination
SCADA & Controls
- Turbine OEM interface
- Client control system integration
- Communications fibre network
- Power quality metering
LV Systems
- Auxiliary LV distribution
- 110 V DC battery chargers
- Lighting, heating, fire and intruder systems
- Compound lighting and control panels
Partnerships
- Fred Olsen Renewables — Client & owner
- R.J. McLeod — Principal civil contractor
- SP Transmission (SPT) — 132 kV grid connection
- Powersystems — EBoP contractor (design, installation, testing, commissioning)
Key Risks & Mitigations
- Challenging weather & terrain – Mitigation: Robust sequencing, weather‑resilient installation methods, strict HSEQ controls.
- 132 kV grid compliance and interface – Mitigation: Detailed protection studies, PoW commissioning, close coordination with SPT.
- Tight energisation programme – Mitigation: Proactive planning, parallel work fronts, early testing packages.
- Integration with existing Crystal Rig II network – Mitigation: Precise protection coordination and SCADA harmonisation.
Environmental Considerations
- 49.1 MW of renewable energy supporting Scotland’s clean‑energy goals
- Low‑impact cabling methods
- Modern, efficient HV/LV infrastructure
- Long‑term carbon reduction via sustainable generation
Economic & Social Value
Over 25 years, Crystal Rig IV will:
- Provide a long‑term community benefit fund
- Support 560 Scottish jobs, including 180 in the Southwest
- Strengthen local supply chains
- Stimulate ongoing investment in East Lothian’s renewable energy economy
Future Prospects
Crystal Rig IV further strengthens the Crystal Rig wind cluster, creating a high‑capacity renewable generation hub in East Lothian.
Powersystems’ successful delivery reinforces our position as the UK’s leading EBoP contractor for major onshore wind developments.
14. Related Projects
- Camster II 36 MW
- Limekiln 108 MW
- North Kyle 212 MW
- Sandy Knowe 86.4 MW
- Douglas West 46.8 MW
Delivering a 132 kV wind farm extension or major EBoP project?
Speak to Powersystems for complete HV design, installation, protection, SCADA and grid‑connection expertise.