Location: Gateshead
Project length: Three months
Client: M. H. Southern & Company
Services: Independent Connection Provider (ICP)

As an Independent Connection Provider (ICP) we were able to go out to market to negotiate a significant cost saving from the client’s incumbent Distribution Network Operator (DNO) enabling a 25% reduction in grid connection costs.

Project details

Redeveloping and enlarging an existing site provided an opportunity for M. H. Southern to merge their production sites into one facility in Gateshead. With the full project taking less than a year, the move was completed by December 2019, including the relocation of over 4,000m3 of stock. We became involved in the project in June 2019, and finished on site in September 2019, following the installation of an 11kV, 500KVA, substation with a single point, low voltage, 800 amp supply to the sawmill. We collaborated with the client to understand the historical energy usage and proposed an INDO adopted solution, significantly reducing their connection costs., as well as cutting the project timescale from 7 to 3 months.

The site was operational during the build of a new production facility and sawmill, creation of fully covered storage space and the installation of new preservative treatment tanks. We enabled this to happen through the provision of an alternative feed throughout the works.

We’re proud to have contributed to the smooth running of the business throughout the project. Delivering a connection on time and on budget was crucial to the client’s requirements to ensure they could meet customer orders, and we’re pleased to have supported another UK business in achieving their goals.

The post ICP works for Green Lane Sawmills appeared first on Green Frog Connect.

Since 2004, Air Liquide has provided bulk gases to the manufacturing, pharmaceutical, food and beverage industries. They recently moved their UK production plant to the Midlands, so their existing manufacturing facility required an increased power supply. Green Frog Connect successfully installed a new 20MW 132kV connection, enabling the business-critical factory upgrade to go ahead.

Location: Birmingham
Client: Air Liquide
Services: ICP, Engineering, Procurement, and Construction services, Customer balance of plant construction and commissioning.

Project details

Bounded tightly by a railway line, existing on-site industrial operations and a working car park, the site for our latest HV installation presented our project team with some interesting challenges. From contract award successful energisation was achieved within the targeted twelve months program.

Once work began on site, several unexpected and unmarked and significant Victorian culverts were discovered running beneath the planned cable route and throughout the client’s site which created additional design challenges. Local network fault levels also presented the opportunity for an innovative earth design solution to mitigate against any resultant imported Hot Zone contours across the adjacent Network Rail track. Our technological approach prevented what would otherwise traditionally have required a disruptive redesign of the client’s site and a significant impact on the overall project delivery.

Throughout the project it was vital that existing production services were able to continue as normal. Our team led the complex logistics required to ensure our client experienced no operational impact from our works. We liaised with all other parties working across the clients site build to ensure all works dovetailed seamlessly with each other to ensure completion ahead of the client’s scheduled on-site plant commissioning.

We’re delighted to have played a central part in delivering this 132kV connection which enabled the upgrade of their manufacturing facility.

Click here to watch the site develop on Youtube.

The post 132kV connection for Air Liquide appeared first on Green Frog Connect.

The existing DNO metering substation supplying the factory required a generator constrain panel for the solar farm which was located some two kilometres away. Our challenge was to find a reliable solution to transfer the constraint signals to the solar park.

Our solution was to use a fibre cable, complete with programable converters, to transform the hardwired volt free contacts via the ethernet. Due to tight client deadlines, and typical manufacturer availability, we designed and built the required panels mirroring each other at the remote ends. A built-in watchdog for continuous monitoring ensured any failure in communication would curtail generation and avoid tripping of any existing factory supplies. Each panel is built with an integrated supply unit with battery support should external supplies fail.

The post Rising to the challenge appeared first on Green Frog Connect.

Essential Infrastructure Installation

Green Frog Connect will be carrying out essential high voltage infrastructure installation to be connected to Electricity North West Limited’s primary substation in Preston East (off Bluebell Way, opposite the Premier Inn hotel). The purpose of this electrical installation works is to ultimately provide operational reserve to balance the National Grid’s demand for power during high usage periods and to assist during outages of major power stations.

The installation of this 33,000 Volt electrical circuit will commence within the Red Scar Business Park. Works on the public carriageway will see this installation commence from:

1. Adjacent to the B6243/B6242 roundabout towards the roundabout adjacent to the Shell/SPAR service station.
2. The roundabout adjacent to the Shell/SPAR service station towards the Premier Inn hotel off Bluebell Way

We have had various consultations with the Highways team at Lancashire County Council in order to ensure that disruption is kept to a minimum at all times. We will be carrying out the works during daytime hours within the central reservation and any deviations from that will be carried out at night and during the weekends. We will maintain access to service roads although this may restrict the width of the access point. Right/Left turns will be affected when crossing these junctions and, in that case, the roundabouts at both ends (B6243/B6242 junction and one adjacent to the Shell/SPAR) must be utilised to turn around. A Temporary Traffic Regulation Order (TTRO) has been submitted to the council which is subject to a consultation and notice period prior to commencing works that would affect this.

Should you need additional width to gain access across our work area during the day please speak to the staff on site who will be only be pleased to accommodate your request where possible.

We will do our best to keep disruption to an absolute minimum. If any issues do arise during the course of the works, please speak to the staff on site or feel free to contact myself directly as an alternative where I will endeavour to accommodate your requests or answer any queries. The works within the public carriageway are currently due to start on 16th September 2019 lasting all the way through to 17th January 2020.

Weekly status update

2nd November 2019

We have made incredible improvements to the programme which has seen us complete the duct installation on this scheme 5 weeks ahead of schedule. The last section through to the exit point of the cable route within the business park shall be tarmacked tight over Monday 4th Nov. From week commencing 4th Nov, through to the first week of December, we will be excavating joint bays in order to carry out jointing of the circuits; whilst this may cause some disruption, this is only likely to be minor. We don’t foresee any road closures or diversions within the Red Scar business park. As the works are now coming to end and no major disruptions envisaged, this will be the last of our weekly updates; however, if the situation changes, we will continue to provide timely updates as required.

As always, should you have any questions or concerns, please don’t hesitate to get in touch.

26th October 2019

We have the last 69m to excavate, duct and reinstate within the Redscar business park from points D to E. We anticipate that this will be completed by Sunday 3rd November after which we will focus on the cable installation and the electrical jointing works to be carried out up until the first week of December. Whilst this is largely dependent on the logistics associated with the delivery of the cables, we hope to see an overall improvement to the programme by approximately 3 weeks. On a complicated run such as this, there is no doubt that this is an accomplishment which is a testament to everyone involved. We will continue to keep everyone that may be affected by the works abreast of any development. As always, should you have any queries or concerns, please don’t hesitate to contact me.

19th October 2019

When we put our usual update last week, we envisaged that we would be completed to point 10 and that is what we achieved by Friday 18th October. We understand that it has been a little chaotic over the main entrance especially for large wagons. Having taken this into consideration, we have decided that we will be carrying out the key crossing to point A over the weekend. Realistically, by Friday 25th October, we aim to reach point B. Although this is a major improvement from the overall programme, we are entering complicated parts of the route where it has been difficult to maintain previous progress owing to traffic management, maintaining access to businesses, avoiding existing services, manholes, etc. We continue to appreciate your patience and hopefully this all concludes very soon. As always, should you have any concerns or queries, please don’t hesitate to get in touch.

11th October 2019

Last week, our plan was to complete ducting and reinstatement up to point 8; however, due to the continuous improvements we have been making, we have gone beyond and are half way towards 9. For week commencing 14th October, we anticipate that we will excavate, duct and reinstate up to point 10. Many thanks for your continued patience.

4th October 2019

We will excavating, ducting and reinstating between section 7-8 from week commencing 7th October 2019 within the Red Scar Business Park. With the exception of the culvert that we have found, we are making good progress on site and are constantly making improvements where possible by working out of working hours and over weekends. As you may notice, we had only intended to complete points 5 to 6 on week commencing 30th September; but had managed to complete sections 6 to 7 too. This is testament to the on ground teams’ hard work and proactive efforts. Many thanks for your continued patience.

30th September 2019

We will be working within the Red Scar industrial estate from points 5 to 6 over the course of week commencing 30th September.As we have stumbled upon a potentially disused culvert that covers the entirety of the width of the road, we are currently engaging with Electricity North West Limited and other experts on the best way to cross this. This may be core drilling or through means of a directional drill. We continue to explore the best and safest way to do this. Once this is determined, a revisit to work on this section of the road will be required.

Red Scar Business Park

Contact

Zamil Imam
Project Manager
01142 138 062
redscarstreetworks@greenfrogconnect.co.uk

The post Red Scar Business Park appeared first on Green Frog Connect.

You can find more details on the project here.

Click here to watch the site develop on Youtube.

The post Timelapse of Swansea West site construction appeared first on Green Frog Connect.

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.

The post Green Frog Connect marks a major 1500MW milestone appeared first on Green Frog Connect.

With over 20,000 hours worked, the project included very high risk work including excavations, major crane lifts, high voltage works and working at height. Early site clearance works were initiated in January, in anticipation of the auction, with full mobilisation immediately following the results. Design and planning works had already been completed well ahead of the auction.

Tom Drake, Director of Green Frog Connect, said, “This project demonstrates the impact of our commitment to the continuous improvement of Health and Safety practices. We’d like to thank all our team, and our sub-contractors, who have worked together to maintain high safety standards whilst delivering the project ahead of schedule.“

The construction of this small-scale gas fuelled capacity mechanism embedded power plant, within a 2,400m2 compound, included the construction of foundations to accommodate electrical equipment including generators, transformers, the switchroom and containerised units. High and low voltage cabling has been routed around the site, which is bordered by a sheer cliff on two sides, a site of special scientific interest (SSSI), and a busy industrial estate.

Adrian Sherman, Green Frog Connect’s SHEQ liaison on the project, said, “Considering the number of working hours and all the hazards faced throughout the construction of the site, this is a fantastic achievement which we are rightly very proud of.“

Despite the challenges and tight timescales, the site was generating and available for export from mid-September and is now available to respond to Capacity Market Warnings issued by National Grid. The Capacity Market exists to ensure long-term security of supply by ensuring there is sufficient generating (or demand reduction) capacity at times of system stress, for example when renewable sources are not producing at a time of high demand.

The post Plymouth project completes ahead of schedule with zero injuries appeared first on Green Frog Connect.

Location: Swansea West
Capacity: 40MW
Project length: Seven months
Client: Green Frog Power

Key client benefits

• We designed and negotiated a simplified connection arrangement which saved the client in excess of £500k compared to their original arrangement.
• We diverted a private overhead line that was originally routed through the site and managed all outages to ensure that the businesses being fed did not lose supply.
• A shared electricity and gas trench for the off-site connections was coordinated to minimise costs and reduce the amount of disruption to the local community.

Time-lapse of site build

Click here to watch the site develop on Youtube.

The post Swansea West gas-fired power generation appeared first on Green Frog Connect.

Location: County Durham
Capacity: 12.5MW
Project length: Seven months
Client: Airvolution Energy Ltd

Key client benefits

• Completed on time, allowing the client to meet their RoC tariff deadline.
• On budget and achieved a significant saving compared to the DNO offer.

Project details

The project comprised of the excavation and laying of two 11kV cables and telecommunication cables in a common trench from Northern Powergrid’s 66/11kV Substation to the 11kV Metered Ring Main Units, housed in the intake substation situated on the wind farm. Our services covered the design and installation of new 11kV apparatus for the Contestable Works, comprising:

• The design and installation of the 11kV substation layout.
• The 11kV switchgear and ancillary apparatus.
• Earthing design of the 11kV substation.
• The design of the 11kV cable systems and protection systems.

Located in County Durham, the greenfield site is surrounded by private agricultural land and woodland areas, and it was necessary for a short section of the cable route to pass under a river. Green Frog Connect installed this cabling in ducts using Directional Drilling techniques.

The post Red Gap Moor Wind Farm appeared first on Green Frog Connect.

Location: Gloucestershire
Capacity: 40MW
Project length: Nine months
Client: Viridis 178 Ltd

Key client benefits

• Worked closely with all stakeholders to complete a directional drill under the River Severn and a major oil pipeline crossing on budget and on time.
• Developed an innovative solution to deal with asbestos when it was unexpectedly found on site, resulting in no cost impact for the client.

Project details

Over nine months, Green Frog Connect acted as the principal contractor as well as the Independent Connections Provider. Our services comprised:

• The design and construction of the electricity grid connection contestable works, including a single 40MW tee-off connection to the Western Power Distribution 33kV network.
• The design and construction of the balance of plant, including switchgear, transformers, power cabling systems, SCADA/control system, the auxiliary power system and a security system.
• The design and construction of the civil works including ground works, reinforced concrete structures, fencing and access roads.

The installation and commissioning of the 27 GE Jenbacher Generator Sets, and the gas connections, were undertaken by Green Frog Genovate and Green Frog Gas Utilities respectively. The site is now dispatched by Green Frog Trading to ensure Capacity Market events are met, and also operates on the open market providing power at times when renewable generation is low, and/or when demand is high.

The post Sudmeadow Road Gas-fired Generation Plant appeared first on Green Frog Connect.