High‑voltage substation, LV infrastructure and CHP integration for industrial on‑site generation
Project Snapshot
| Project Detail | Information |
| Client | BasePower |
| Location | Plastic Omnium, Omega South, Warrington, WA5 3TP |
| Project Value | £109,558.11 |
| Project Duration | Jun 2020 – Sept 2020 |
| Services | 11 kV Substation, LV Electrical Infrastructure, CHP Connection |
| Market Sector | Cogeneration / Industrial Manufacturing |
| Installed Capacity | 1.0 MW CHP |
| Connection Voltage | 415 V (LV) interfacing with private 11 kV network |
| Powersystems Role | HV/LV design, installation, testing, commissioning, SAP provision |
| Powersystems Fact | This project was the first of four CHP schemes delivered for BasePower during the year, strengthening a long-term, trusted partnership. |
Plastic Omnium Warrington 1.0 MW CHP Case Study
Download the full Plastic Omnium Warrington CHP Case Study — ideal for engineers, developers and technical stakeholders. This summary outlines the 11 kV substation connection, transformer installation, LV distribution, protection programming, cabling, containment, and G99 commissioning delivered by Powersystems for the 1.0 MW CHP system. The full document provides technical insight into HV/LV design, earthing, protection coordination and SAP‑managed energisation required to integrate CHP plant into an active industrial environment.
Client & Site Background
Plastic Omnium is a major automotive component manufacturer operating energy‑intensive processes at its Omega South site in Warrington. As part of its sustainability and cost‑reduction strategy, the business invested in 1.0 MW of on‑site CHP generation, enabling it to reduce reliance on grid supplies and enhance operational resilience.
BasePower partnered with Powersystems to design and integrate the electrical systems for the new CHP substation and generator.
The Challenge
Plastic Omnium required a fully integrated CHP electrical connection that could:
- Interface safely with the factory’s private 11 kV SPEN‑connected network
- Install a new 1250 kVA 11/0.415 kV transformer within an active industrial environment
- Complete works during strict COVID‑19 restrictions
- Meet immovable energisation and G99 testing dates
- Seamlessly integrate with existing LV infrastructure
- Provide precise import/export control and protection
Powersystems were appointed as the HV/LV contractor for the full substation and CHP electrical package.
Our Engineering Solution
Powersystems delivered the complete electrical infrastructure for the CHP project, including:
- Installation of a GBE 1250 kVA 11/0.415 kV transformer
- Close‑coupled Schneider RN2d‑T2 RMU with MU2 metering unit
- 11 kV cabling and HV terminations to the existing factory network
- 415 V CHP connection to a Schneider Masterpact G99 breaker
- Custom Power Measurement Panel for import/export and constraint signals
- Earthing study and full earthing installation
- LV distribution to pump kiosks and auxiliary systems
- Protection programming and relay coordination
- LV, control, signalling and communication cabling throughout the CHP site
- SAP‑controlled energisation and G99 testing
The system was carefully designed to deliver efficient and safe CHP operation, supporting continuous parallel generation with the grid.
Project Process
- HV/LV engineering design, protection coordination, earthing and substation layout
- Transformer, RMU and metering unit procurement
- HV/LV cabling installation (including controlled shutdown for CT installation)
- Custom measurement panel fabrication and integration
- Containment installation and cable routing across factory infrastructure
- System testing, LV certification and functional checks
- SAP‑managed energisation (27 Aug 2020)
- G99 testing (9 Sept 2020) and first export (10 Sept 2020)
Project Facts & Figures
- Generator: 1 × 1.0 MW MTU 8V4000 GS CHP
- Transformer: 1250 kVA 11/0.415 kV
- Connection Voltage: 415 V / 11 kV
- 11 kV cabling: 0.10 km
- 400 V cabling: 0.20 km
- Control & signal cabling: 0.40 km
- Altitude: 49 ft
- NERS Accredited ICP: Yes
Technical Specifications
Major Electrical Installations
- 1250 kVA Dyn11 transformer & bund
- Schneider RN2d‑T2 RMU with metering
- CHP 415 V feeder into Masterpact G99 breaker
- Power Measurement Panel with BMS interface
- Auxiliary LV distribution connections
- Earthing grid and bonding
- LV, control, signal & SCADA wiring
Design & Engineering Works
- HV CT installation design & controlled shutdown plan
- LV containment design (ladder, high‑level routing)
- LV earthing and CPC design
- Cable sizing / fault level calculations
- Protection study incl. grading and relay curves
- LV cable route mapping and drawings
- Control & signal wiring schematics
Commissioning Activities
- Transformer cold commissioning
- RMU functional tests
- LV installation certification
- Insulation resistance testing
- G100/G99 DNO witness testing
- Full integration testing with 2G CHP controls
Partnerships
Delivered alongside:
- BasePower – Client
- Nijhuis Construction – Civil and site works
- 2G Energy Ltd – CHP engine supplier
- Scottish Power Energy Networks (SPEN) – DNO interface
This was the second CHP project delivered for BasePower that year, reinforcing long-term collaboration.
CHP Development
The CHP installation enables:
- On‑site power generation at significantly reduced cost
- Hot water and steam from waste heat
- Lower carbon emissions through co‑generation
- Energy efficiency improvements of up to 45%
Key Risks & Mitigations
- COVID‑19 restrictions → Safe‑working protocols ensured continuity and programme adherence.
- Constrained factory environment → High‑level containment across pipe bridges ensured safe cable routing.
- Strict energisation and G99 deadlines → Prioritised sequencing ensured zero delays.
- High‑fault‑level 11 kV environment → Detailed protection studies ensured network compatibility.
- LV switchboard integration challenges → Custom AIB installation allowed safe CHP interfacing.
- Limited shutdown windows → SAP‑managed switching minimised operational disruption.
Environmental Considerations
- Reduced greenhouse gas emissions
- Less reliance on grid power
- Lower transmission and distribution losses
- Enhanced factory energy efficiency
Economic & Social Value
- Lower energy bills through CHP generation
- Improved operational resilience
- Reduced exposure to electricity price increases
- Revenue protection through dependable on‑site power
Future Prospects
The CHP substation and electrical works were completed on time and within budget, with first generation achieved on 10 September 2020. The project strengthened Powersystems’ long‑standing partnership with BasePower and demonstrated efficient delivery under challenging conditions.
Related Projects
Powersystems deliver specialist HV/LV infrastructure for CHP, industrial power systems and on site energy generation across the UK.
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