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Projects

Proven Experience. Delivered in the Field.

Explore a selection of high voltage projects delivered by HVAI across renewable energy, industrial and private network infrastructure.

Renewables

Cowley Solar Farm - 132kV Teed Connection

High voltage electrical installation works for a 49.9MW solar farm connection incorporating 132kV and 33kV infrastructure.

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49.9MW 132kV

Industrial & Waste

Biffa Waste Management – Transformer Upgrade

11kV 2.5MVA amorphous transformer upgrade and cable reconfiguration.

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11kV 2.5MVA

Cowley Solar Farm — 49.9MW 132kV Teed Connection

Client

Independent Connection Provider (ICP)

Voltage

132kV / 33kV

Sector

Renewable Energy

Project Overview

HVAI delivered high voltage electrical installation works for the Cowley Solar Farm project, a 49.9MW solar development incorporating a 132kV teed connection and associated 33kV infrastructure. The project demonstrates HVAI’s capability to deliver complex high voltage works for large-scale renewable energy infrastructure.

Scope of Works
Protection and control wiring design, installation and pre-commissioning
Installation of cable containment systems (tray, ladder rack and ducting)
Internal substation earthing system installation and testing
Installation of protection, control and metering panels
33kV and LV cable installation, termination and testing
Associated cable management and support systems
Key Challenges
A compressed programme driven by the solar farm's energisation deadline
Strict compliance requirements to meet DNO adoption standards
Coordination with multiple stakeholders, including the ICP and network operator
Maintaining high-quality installation standards across all disciplines under time pressure
Delivery & Outcome
Drawing on our high-voltage installation experience, we delivered a well-organised and technically sound solution for the 132kV Solar project on behalf of an ICP for Eclipse Power and Northern Powergrid.
We managed the delivery and installation of the full internal fit out works for both the DNO and the IDNO of the project.
The project was delivered safely, on track with our programme, and in full accordance with the client’s specifications and the Connection Agreement, with zero reportable health and safety incidents.

HVAI delivered the installation to a very good standard, particularly in the areas of protection and control wiring and overall cable management. The site team were organised, responsive, and worked well alongside other contractors to maintain progress against a challenging programme. The quality of the final installation and supporting documentation met the expectations required for network adoption, and we would be happy to work with them again on similar schemes.

Client representative, Independent Connection Provider

HVAI Accreditations Applied

Biffa Waste Management — 11kV 2.5MVA Transformer Upgrade

Client

Biffa Waste Management

New Rating

2.5 MVA

Sector

Waste Management

Driver

In-service cast resin failure

Core/fluid

Amorphous · MIDEL 7131

Project Overview

When a cast resin transformer failed in service, the site needed more than a like-for-like swap. It was replaced with a 2.5 MVA amorphous-core transformer filled with MIDEL 7131, plus new cabling, secondary containment and modifications to the existing LV panel.

The Challenge
The incoming supply served process plant, materials handling, extraction and site services. When the cast resin unit failed, production stopped. On a waste site that is not a clean indoor problem: incoming waste keeps arriving, odour and fire risk rise, and throughput contracts are immediately at risk.
 
Cast resin is often chosen for fire performance and the lack of insulating liquid. On this kind of site it is still a hard environment — dust, moisture, corrosive air, vibration from shredders and conveyors, and thermal cycling. Partial discharge, surface tracking and winding hot spots can build with little warning.
 
A second dry-type unit would have restored power. It would not have fixed the atmosphere, future load, standing losses, or the state of the tails and LV incoming cell.
The Solution
A 2.5 MVA sealed liquid-filled unit with:
Amorphous core — no-load losses typically 70–80% lower than CRGO. That saving runs 8,760 hours a year on a site transformer.
MIDEL 7131 — IEC 61039 Class K3 synthetic ester. Fire performance close enough to dry-type to sit inside operational.
Sealed tank — windings not open to site dust and humidity.
2.5 MVA — headroom for process growth instead of returning to the old constraint.
Scope of Works
Survey, load review, protection study, containment design, cable sizing, outage plan
Isolation, removal of the failed cast resin unit
New 2.5 MVA amorphous / MIDEL 7131 transformer (ONAN, OTI, PRD)
New LV cabling — busbars from the failed unit were not reused.
Existing LV panel modifications transferring from busbar connection to cable connection.
FAT review, site tests, protection injection, staged load pickup, handover pack
Results
Supply restored inside a planned outage
Capacity lifted to 2.5 MVA
Standing losses cut by the amorphous core
Fire/environment position improved (K-class ester)
Protection and records matched to the unit that is actually installed
On a continuously energised 2.5 MVA transformer the no-load improvement is typically tens of MWh a year.
Standards Applied

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