IUS undertook the design, procurement, installation, and commissioning of the Northern Powergrid (NPg) contestable works, which comprised the 11kV Ring Main Unit and the associated 2 No. 11kV, 300mm triplex cables. These cables were installed on private and public land to the NPg point of connection. This element also included the design and installation of the earth nest for the whole substation to NPg specifications.

IUS also undertook the design, procurement, installation, and commissioning of the IDNO (ESP) element of the project which comprised the transformer with close coupled ACB. IUS also advised the client with regard to the overall construction of the substation and the standards required by both the DNO and the IDNO in order for the adoption by both parties to be achieved.

The substation was tested, commissioned, and energised with the appropriate apparatus adopted by NPg and ESP.

The project involved extending the DNO’s local 11kV network c. 220m to a point on Unilever’s site and supplying and installing a new 11kV intake substation complete with an 11kV metered ring main unit.

Modifications to the existing 11kV private network were required to facilitate the connection upgrade as well as the supply and installation of an 11kV switchboard, local 11kV ring main units, 11,000/433V transformers and a low voltage switchboard. Due to the nature of the site, IUS were required to work to a tight programme. The contract was delivered to the agreed timescales.

IUS project managed the installation of the substation building to specification. The 115- meter feeder route encompassed 2 x 185mm aluminium 20kV XLPE Triplex cables to the point of connection onto the NPg network. Cable trenches were excavated on both private land and the public highway. IUS HV electrical fitters completed the installation of a 20kV
ABB safe plus ring main unit, 500kVA transformer with close coupled LV cabinet, earthing, protection, and metering cabling. IUS HV Jointers carried out the HV cable terminations. An IUS protection engineer conducted the pre-commissioning and witness testing for NPg. The IUS Senior Authorised Person provided the necessary safety documentation and oversight of the works. Customer LV sub mains cables were installed from the substation into the factory on high-level containment to supply a new low-voltage switchboard. Existing factory supplies were reconnected to the new switchboard during a planned outage giving the customer scope for their future expansion plans.

IUS completed the design of the 11kV system earth installation, including ground surveys and testing to ascertain the ground resistivity around site to be used in the earthing model. All earthing apparatus was installed to the design resulting in compliant earth nest readings.

A protection and grading study was undertaken of the 11kV network from the Northern Powergrid (NPg) metering breakers, through the customers intake 11kV switchboard and transformer, including the largest LV ACB’s, to ensure correct protection and grading for the new 11kV system.

Following design, a new client owned 11kV intake substation, comprising a 7 No. panel extensible switchboard, was supplied and installed at the perimeter of the site. Also installed were 2 No. 11kV 300mm Copper Triplex cable loops between the clients’ switchboard and the NPg switchgear in the adjacent rooms. This also included liaison with NPg on the final connections and operational requirements to ensure a seamless “power on”.

The scope of services also included the supply, installation and commissioning of 12 No. 1500kVA, 11000/433V transformers and 2 No. 1000kVA transformers, all with close coupled 11kV ring main units, installed within 4 No. substations around the site.

To create 2 x 11kV rings, IUS supplied and installed 4.5Km of 300mm Aluminium 11kV Triplex cable to provide connection between the clients’ new intake substation and the 4 No. aforementioned substations.

IUS is contracted to provide planned and reactive operation and maintenance services at three UK windfarms operated by EnergieKontour.

The contracted sites are:

• Burton Pidsea Windfarm in East Yorkshire, which comprises of three turbines with a capacity of 10.2 MW.
• Withernwick Windfarm in East Yorkshire, which comprises of nine turbines with a capacity 18.45 MW.
• Lilbourne Windfarm in Northamptonshire, which comprises of five turbines with a capacity of 10 MW.

Site operations and activities are coordinated with the EnergieKontour control facility in Germany.

IUS services on these and similar contracts comprise of network operation, site inspection, planned maintenance and fault management and repair.

The project involved the supply and installation of a specialised multi-part GRP enclosure, which reduced construction costs and on-site installation times. Within the GRP housing, 33kV Schneider Electric WS switchgear was installed with connections made to the extra high voltage cable circuits using Pfisterer terminations. The design, installation, and commissioning of all associated DC and control systems also formed part of the IUS work scope.

The contestable connection design required the installation of 18km of 33kV cabling across two feeders between the existing Distribution NetworkOperator (DNO) point of connection and the new windfarm. The route was across soft peat and through mature forestry. Due to environmental restrictions the works were completed in December and January, which presented additional challenges.

The use of cable ploughing techniques and low ground pressure bearing equipment significantly reduced the installation timescales and disruption to the ground conditions. A Hagglund ATV was deployed to ensure safeaccess and egress to the sites at all times.

The project involved the construction of a combined building to house the 33kV NPg intake substation equipment and the customer owned 33kV switchgear.

The 33kV cable route to the new substation required the crossing of the Hull–London Railway Line by Horizontal Directional Drilling (HDD) methods. The IUS scope of works included all negotiations with Network Rail, HDD design and settlement calculations, possession planning and drilling operations.

The private electrical infrastructure installed by IUS included; 33kV, pilot and LV single core cables; a three panel 33kV switchboard; protection equipment; substation ancillary apparatus and two 2.5MVA containerised substations on raised platforms (flood risk mitigation).

Following significant reinforcement of the local 11kV network by SSEN, a suitable point of connection was identified for IUS to utilise.

IUS designed, supplied and installed the 3 core 150mm 11kV polymeric (LLDPE) cable circuit, from the overhead line point of connection, terminating at the HV switchgear controlling the 11,000/433V, 500kVA ground mounted transformer. The substation apparatus was located within a new purpose-built GRP housing. A LV supply was provided from the switchgear to the SW kiosk within the site. All apparatus was tested by IUS prior to energisation.

IUS fulfilled the role as Principal Contractor for the works and undertook all cable joints and terminations. Active engagement was maintained with all third parties, including SSEN to ensure that the works were completed to their requirements and to client timescales.

The project involved installing a new 11kV supply c.3.5 km away from the Point of Connection (POC) issued by Scottish Power due to the remote location. In order for IUS to meet Scottish Water deadlines we installed the cable within adoptable carriageway. The cable route included crossing a motorway bridge over the M77, grass verge adjacent to the A77 and a single track carriageway along Highfield Farm Road. IUS also had to carry out directional drilling under four water crossings due to insufficient depth on the bridges. The area where the new Drumboyhill tank is located was within a area of heavy peat, so specialist equipment was required to excavate as well as access the wood pole for the transformer work.

IUS were engaged as Principle Designer on this project and had a full time Coordinator along with a Project Manager and HSQE Advisor, working in collaboration. Two additional Contractors were working in the area, therefore close engagement and coordinated programming of works were of high importance.

All works on site were completed on time, within budget and were handed over to the Distribution Network Operator for adoption on energisation.

The project involved the provision of a bespoke GRP enclosure to house the Distribution Network Operator (DNO) 5 panel 11kV switchboard, with the clients 11kV switchgear located within the fabric of the main Pump House, constructed by others. Two independent 3.6MVA circuits were provided from individual primary substations on the DNO 11kV network.One feeder for normal service conditions and one circuit for security of supply in the event of a fault on the principal supply.

Both 11kV cable routes to the Pumping Station involved extensive excavation over circa 7km, including under three railway bridges and over numerous road bridges. This required additional engineering solutions to negotiate. The IUS scope of works included interface with all stakeholders, most notably Network Rail, local councils, the DNO, SEPA, as well asScottish Water. The private electrical infrastructure installed by IUS included an eight panel 11kV switchboard, three 2MVA transformers, one 0.8MVA transformer, 11kV cabling, control/metering wiring, electrical protection and substation ancillary equipment.

The works necessitated the installation of new H-Poles adjacent to the existing Scottish Power Energy Networks (SSEN) overhead line. These Hpoles would accommodate the installation of a 33,000/433V, 200kVA pole mounted transformer (PMT) and associated components. From the LV side of the PMT, a LV cable was laid to the new RWPS kiosk, terminating in a cutout beneath the installed current transformer metering panel. 

The feeder route necessitated a road crossing. To minimize disruption to traffic flow on the A82, the road crossing was undertaken by directional drilling.

Extensive engagement with SSEN was maintained throughout the duration of the works to ensure full compliance with their adoptable standards. On completion the substation was energised and the RWPS is now in full operation.

IUS undertook full design duties and operated as Principal Contractor (PC) for all our site works, liaising closely with Scottish Water’s own PC for the main development.

Following extensive engagement with Scottish and Southern Energy Networks (SSEN) the Distribution Network Operator, IUS was able to develop several service options to facilitate the connection to the WTW.
Within these options key considerations with other stakeholders were required, including with Forestry Commission Scotland, due to the sensitivities of the area.

IUS supplied and installed new 33kV overhead line construction. Approximately 950m of 95mm single core (triplex) aluminium 33kV cable was laid below the Forestry Commission Scotland access track, terminating at a ground mounted substation, which included a 33,000/433V, 500kVA transformer. A 300mm 4 core aluminium Wavecon cable was installed from the substation transformer, terminating at a 600Amp fused cut-out beneath the LV current transformer metering panel. The full HV and LV network was designed, procured, installed, tested and commissioned by IUS. On completion of the works to the adoptable standards of SSEN, the substation was energised. The WTW is now in full operation.

The works were undertaken during weekends only, to avoid disruption to the main site works.

Over 500m of excavation, duct laying, cable installation and full reinstatement was undertaken by IUS from the SPEN point of connection to site. Point of connection identification, jointing and cable testing were also completed in accordance with SPEN specifications.

IUS fulfilled the role as Principal Contractor for the connection, implementation and management of all works associated with the project, including a rolling traffic management scheme to align with the progress of the works.

IUS effected all communication and liaison with the residents and key stakeholders, ensuring full awareness of the works, their progress and successful completion.