Location: UK wide
Client: AMP Clean Energy
Services: ICP, Engineering, Procurement and Construction services

Project details

The purpose of the project was to help support the growth of renewables by providing energy on-demand when the wind doesn’t blow and the sun doesn’t shine. This helps to balance the electricity grid ensuring that enough power is generated whilst supporting the transition to a low carbon economy. Green Frog Connect were appointed to act as the ICP for grid connections and as EPC for the construction of the six gas peaking power plants as part of AMP Clean Energy’s Urban Reserve project.

We faced a challenge in that all of the sites were located on brownfield industrial estates. Using our expertise we saved space and ensured that all sites were built to the highest safety standard whilst accommodating multiple activities. The first project began in late 2020 with each following mobilisation taking place on a weekly basis. The first site became fully energised in March 2021.

All six sites were up and running simultaneously and throughout the project Green Frog Connect demonstrated the depth and flexibility of our construction teams to ensure that AMP Clean Energy was confident in our delivery promises.

Our initial appointment was to undertake the contestable design and place orders for long lead time equipment. The client’s gas engines and HV switch room had already been ordered which helped to reduce construction activities to 20 weeks per project. We had full responsibility for the contestable works, site civil construction, the electrical balance of plant installation and co-ordination of the full site commissioning through to client handover.

Green Frog Connect managed to maintain momentum across the project and ensured all sites were connected on time and within the budget set by the client. We worked closely with the client’s Original Equipment Manufacturer (OEM), co-ordinating all activity with the Distribution Network Operator to ensure that the client’s route to market was achieved at the earliest opportunity.

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Location: Leicestershire
Project value: £350k
Services: Construction services, design

Our innovative technical solutions resulted in a vastly reduced project lead time and subsequently significant cost savings for the client.

Project details

Demonstrating the company’s commitment to implement more resource-efficient methods in its manufacturing process, the ‘hard-wired’ solar development will provide 30% of the site’s annual electricity demand, enabling the facility to reduce its carbon footprint and reliance on the national grid.

Green Frog Connect were responsible for the turnkey design and installation of the 11kV cable that connects the solar park to the factory, as well as an extension of the existing 11kV switchboard which allowed the solar park to be integrated into the factory’s existing network.

The project, which in part aimed to address the company’s sustainability concerns, was made technically challenging as the solar farm is located some distance from the factory itself. The existing Distribution Network Operator (DNO) metering substation supplying the factory required a generator constraint panel for the solar farm which was located two kilometres away.

In partnership with the rest of the project team, our challenge was to find a reliable solution to transfer the constraint signals to the solar park. With tight client deadlines and restrictive manufacturer availability, we designed and built our innovative technical solution in-house.

Using a fibre cable, complete with programmable converters, we were able to transform the hardwired volt free contacts via the ethernet. Our technical specialists designed and personally built the required panels mirroring each other at the remote ends. Each panel is built with an integrated supply unit with battery support should external supplies fail. We addressed any potential failure in communication by building in a watchdog for continuous monitoring to curtail generation if required to avoid tripping of any existing factory supplies.

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In recognition of our cleaner and more flexible solutions making a significant contribution to the UK meeting future renewable energy and carbon reduction targets, we’ve been awarded a significant amount of Research and Development tax credits. Part of a government incentive to reward UK companies for investing in innovation, the tax credits are there to reward companies taking a risk by attempting to ‘resolve scientific or technological uncertainties.

“Innovation is at the heart of the UK’s energy transition”, says Richard Shearer, our Managing Director. “It touches all parts of the energy system, from policy frameworks to business models, infrastructure to deployment. Improving the end to end process is essential to us all working together to create a zero-carbon energy sector. Whether we’re looking at single small technical solutions or driving a large-scale technology breakthrough, it’s great to be recognised for research and development which is ultimately helping us all to realise the vision of a reduced carbon energy system. Our team of competent professionals have made some recent advances within our mechanical and electrical engineering designs helping to increase the overall knowledge and capability in the field, by providing a precedent and repeatable process. Our teams relish the opportunity where there is a technological uncertainty or no existing knowledge and have a track record of creating new advances. The team is at the forefront of the energy sector driving innovations to deliver efficiencies across the industry and a reduction in installation programme times”.

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Helvellyn will own and operate the new network, constructed by independent connection provider Green Frog Connect at a new plant in Leeds.

Stewart Dawson, the managing director of Vattenfall Networks, said: “The first of anything is always precious so we are of course delighted to partner with Helvellyn and own and operate the new electricity network at its Leeds plant.

“We believe our competence and experience brings customers, such as Helvellyn, peace of mind to get on with their business. Our new team will be focused on delivering the right solution with Green Frog Connect, Helvellyn’s independent connection provider.”

Tom Drake from Green Frog Connect, added: “We’re delighted to have been appointed as the ICP for this project. It’s a first of it’s kind for both Helvellyn – their first alternative fuel production plant in the UK, and for Vattenfall – their first IDNO network in the UK, so we’re looking forward to bringing Green Frog Connect’s experience to the project.”

The scale of the independent distribution network sector has grown considerably since energy regulator Ofgem opened the market for connection and operations more than ten-years ago. Last year the market grew by 26%, from 600,000 to over 750,000 connections.

Helvellyn’s processing plant will see a new 11kV connection, with an import capacity of 5 mega volt amps. The design produced by Green Frog Connect will be adopted by Vattenfall Networks once the connection becomes live.

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The role of the HCLG is to act as both a stimulus and a catalyst in helping unify the industry in its approach to worker health protection and the promotion, adoption and implementation of best practice processes and initiatives.

You can find out more about the Health in Construction Leadership Group here.

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1500MW represents about 2% of the UK’s electricity generating capacity, and it’s great to know that these were all either renewable energy projects or for flexible power generation. One third of these projects were not only connected by Green Frog Connect, but also built out in their entirety with us acting as the EPC.

“When we started the business six years ago, we made the decision to focus purely on connecting power generation projects, which are more complex and time consuming than connecting residential and commercial developments,” says Tom Drake, Director. “After reaching this milestone it’s clear that this decision has paid off. We now have an incredibly skilled and dedicated team with a deep understanding of power generation grid connections across all DNO areas.”

Having taken the step to become an EPC contractor for flexible power generation, we are well poised to play our part in the UK’s transition to a cleaner, more flexible and increasingly de-centralised electricity system. We look forward to the inevitable rise of battery storage and other types of energy storage such as gas to grid and super capacitors.

Image shows Richard Shearer, Managing Director (L) and Tom Drake, Director, (R) on site at Redfield Road, Nottingham, where Green Frog Connect acted as the Principal Contractor as well as the Independent Connection Provider for a 40MW gas-fired power generation plant, which provides reserve power to National Grid through the Capacity Market.

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Achieving a Silver in the internationally-renowned RoSPA Health and Safety Awards, the company will be presented with the award at a ceremony at Hilton Birmingham Metropole hotel on Thursday, July 5, 2018.

The RoSPA Awards scheme receives entries from organisations around the world and recognises achievement in health and safety management systems, including practices such as leadership and workforce involvement.

“We are delighted to have achieved the RoSPA Silver Award, particularly as this is the first year that we have entered the scheme,” said Rebecca Lewis, Green Frog Connect’s Head of SHEQ. “This award demonstrates our commitment to achieving the highest standards of health and safety management across all of our projects, helping to confirm our place as a leading ICP and EPC within the industry. The team have worked very hard to achieve this standard and I am very proud of everyone’s efforts.”

Julia Small, RoSPA’s head of qualifications, awards and events, said: “The RoSPA Awards are the most highly-respected in the health and safety arena, with almost 2,000 entrants every year, and allow organisations to prove excellence in the workplace, demonstrating a commitment to the wellbeing of not only employees but all those who interact with it.”

The longest-running industry awards scheme in the UK, the majority of awards are non-competitive and mark achievement at merit, bronze, silver and gold levels. Gold medals, president’s awards, orders of distinction and the Patron’s Award are presented to organisations sustaining the high standards of the gold level over consecutive years.

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At Green Frog Connect we want to overcome the perception that engineering is a man’s world. It shouldn’t be about gender, but about passion for a subject. The UK has the lowest percentage of female engineers in the whole of Europe, and 90% of those who choose to study the subject at university are male. With an overall shortage of engineers entering the profession, it’s increasingly important that we attract and retain women into an industry which has been traditionally male dominated.

There is still much to be done to work towards solving the gender imbalance in engineering. It won’t be simple and will require the efforts of society as a whole. We’ve taken the opportunity to talk to Rebecca Lewis, our Head of Safety, Health, Environment and Quality, about how she came to be immersed in the energy world.

Why did you want to get into energy and engineering?

I have always been interested in energy and engineering. My father was an electronics engineer so was always fixing things while I was growing up! I have always been interested in the environment and technology, and after finishing university I joined a utilities company in Cardiff. This taught me a lot about electric, gas and water networks and how the grid system works in general. I later joined a connections company who specialised in renewable energy connections.

How did you get into the role you are in now?

Having worked in various roles in the utilities industry, I had an opportunity about 6 years ago to complete the NEBOSH general certificate. I really enjoyed the course and so followed this up by looking for a role in Health and Safety. A couple of years later, I was approached by a recruiter for a Project Manager role in Green Frog Connect, which ended up being a part compliance and part Project Manager role and suited me perfectly at the time. There were only four of us back then so we had to wear many hats! As the company grew, my role developed into Head of SHEQ, and now I manage all of the Health, Safety, Environmental and Quality aspects of the business.

What appeals to you about H&S?

I’ve always been passionate about business processes and the impact of these on business success. Health and Safety management has the same structure where getting the processes and procedures right can greatly affect the chances of everyone going home safely from work. There has been an enormous culture change in the UK since I first graduated, and I enjoy being part of the process. Gradually, people are starting to realise that spending a bit more time on health and safety means that they can actually save time and money in the long run, as well as become more compliant, rather than see it as a burden.

How has the workplace changed in terms of diversity since you started your career?

The workplace is definitely much more diverse than when I started my career. Over the past few years it has become more common to see women out on site, however I still think there is a long way to go. Sometimes I will go to industry forums or meetings and be the only woman present, which I think is a shame. I believe there is likely to be a significant shift in the next few years though, particularly in the health and safety industry, as “soft skills” are becoming more and more important and valued by employers, and women tend to demonstrate these skills more effectively.

What gives you the biggest buzz in terms of coming into work?

Being able to make a difference. As the company is still relatively small, I am able to communicate directly with everyone within the business, from the Managing Director to the subcontractors. My ideas are listened to and I am fortunate that a great number of them have been implemented successfully. I’m also hoping to complete my NVQ Diploma this month, which will enable me to start working towards my IOSH Chartership, which will be another great achievement.

What is the biggest project you have been part of?

I think developing the management systems for the business from a very simple system from the days when we acted solely as a connections contractor for EPC contractors, to where we are now acting as Principal Contractor for a variety of multi-million pound contracts. As part of this, I supported the business in achieving the Lloyds Accreditations for construction and design back in the early days, and more recently the implementation of the ISO 901, OHSAS 18001 and ISO 14001 accreditations.

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