Case Studies – Bowers Electrical Ltd https://www.bowerselec.co.uk Transformer & Motor Supplier Mon, 20 Mar 2023 10:54:53 +0000 en-US hourly 1 https://wordpress.org/?v=6.4.3 https://www.bowerselec.co.uk/app/uploads/2023/02/cropped-MicrosoftTeams-image-4-32x32.png Case Studies – Bowers Electrical Ltd https://www.bowerselec.co.uk 32 32 Powering Europes largest EV charging hub in Oxford https://www.bowerselec.co.uk/case-studies/powering-europes-largest-ev-charging-hub-in-oxford/ Thu, 06 Oct 2022 14:13:20 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1479

Powering Europe’s largest EV charging hub in Oxford

Bowers Electricals have supplied all 3 transformers used to convert 33kV HV electricity to 400V LV electricity as part of Europe’s most powerful EV charging hub at Redbridge Park and Ride in Oxford.

Oxford is home to the newest and most powerful EV Charging hub in Europe. The hub, at launch, provides fast and ultra-rapid charging for 42 electric vehicles. However, it can expand to charge 400 electric vehicles in the future. It will support the estimated 36 million EVs expected on UK roads by 2040.

oxford ev charging hub
“The £41 million urban decarbonisation project delivered by Pivot Power, together with a consortium of global partners and part-funded by the UK government, will unlock significant emissions reductions across power, heat and transport as part of the programme to decarbonise Oxford by 2040 – saving 10,000 tonnes of CO2 every year, equivalent to taking over 2,000 cars off the road, increasing to 25,000 tonnes by 2032.”

Oxford City Council commissioned 1 of the 3 transformers that Bowers provided.

They required a 2500kVA, 33000/400v, Aluminium MIDEL Tier 2 distribution transformer to provide the power infrastructure behind this project.

The transformers, all with slightly different specifications, are powering:

  • 10 Fastned chargers with up to 300kW of power available.
  • 20 7-22kW charging bays deployed by Wenea.
  • 12 250kW Tesla Superchargers will be available for Tesla vehicle users.

This charging hub is set apart from other hubs in the UK as the site is directly connected to National Grid’s HV Transmission network. It is connected via a four-mile underground cable that can deliver 10MW of power to charge hundreds of EVs quickly and simultaneously. All without putting additional strain on the local electricity network or requiring costly upgrades.

Bowers Electricals gave us the most competitive price for the specification and very good service too.

Tina Mould
Oxford City Council
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“Bowers has been involved in several EV Charging projects across the UK. This latest one had its unique challenges but nothing our highly skilled and experienced project teams couldn’t handle. It is fantastic for Bowers to have been involved. This prestigious project will only help the transition to decarbonised transport.” Says Simon Concar, Managing Director at Bowers Electricals.

Have a similar project? Enquire now

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An Emergency Response to a Sinking Transformer https://www.bowerselec.co.uk/case-studies/an-emergency-response-to-a-sinking-transformer/ Thu, 06 Oct 2022 14:12:18 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1478

An Emergency Response to a Sinking Transformer

sinking transformer

Bowers Electricals were brought in to supply a replacement transformer to help get a factory up and running, after their existing unit had sunk into an old Victorian drain.

The end user noticed their transformer seemed to be leaning a little and contacted our customer, Midlands Power Networks, via their 24hr Emergency Response team. Midlands Power immediately sent in a team to isolate the transformer as it was still live!

The Midlands Power team utilised a cherry picker to safely suspend themselves over the transformer to enable disconnection. The unit was carefully extracted from the sinkhole via a crane. A temporary generator was then supplied to keep the customer operational.

Bowers Electricals were contacted to supply a new, replacement transformer. This need to be on a fast turnaround to get the factory running on full capacity with minimal disruption.

We provided a standard Tier 1, 1250kVA, 11000/415v Aluminium, ONAN, Transformer complete with a refurbished 630amp switch RMU all available directly from stock.

The Bowers Electricals Project Engineer that worked on this project said, “We turned this project around in a couple of days after an urgent request by Midlands Power. The new transformer was needed quickly to get the customer’s business back online with minimum downtime.” He then added “I have never dealt with a transformer sinking before, especially with it still being live too – very surprising. With electricity still running through it, it could have serious consequences for the customer. They were very lucky; it could have been much worse.”

“All the oil inside would have been gathered to one side, this would have exposed the HV connections. These are designed to be oil insulated and would make the transformer hot which could cause damage or fire. Not to mention the environmental damage that could be caused if thousands of litres of oil spilt into the drains.”

Need a fast turnaround? Contact the team

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A Cast Resin Transformer for Drax Power Station https://www.bowerselec.co.uk/case-studies/a-cast-resin-transformer-for-drax-power-station/ Thu, 06 Oct 2022 14:10:55 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1477

A Cast Resin Transformer for Drax Power Station

cast resin transformer being lifted into position

Bowers Electricals was contacted by Drax Group in April this year to replace one of their transformers.

Their existing transformer had deteriorated with age and was overheating, causing the transformer protection to trip the circuit breaker. We supplied a 2000kVA Cast Resin Transformer to Selby Power Station.

Specifications:

  • 2000kVA
  • 3300/433V
  • Dyn 11
  • 3 phases
  • 50Hz
  • IP00
  • 6% impedance
  • AN
  • Tier 1
Drax Group operates the largest power station in the UK, based near Selby, North Yorkshire, and generates 12% of the country’s renewable electricity. The energy firm converted its power station from using coal to generating renewable power with sustainable biomass, making Drax Power Station the single biggest renewable generator in the UK and the largest decarbonisation project in Europe.

We (Drax Group) recently purchased a 2000kVA transformer from Bowers. The process from start to finish was handled professionally and promptly. The transformer was carried out to a high standard, complying with the engineering drawings provided making the replacement achievable.

Josh Lynas
Drax Group
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As part of the full Bowers Electricals Ltd service, we offer witness testing to all our clients where they can see the stringent testing that the transformers go through before we deliver them.

“Bowers was accommodating and flexible in providing Factory Acceptance Testing offered either virtually or in person, this was beneficial, giving an insight into the facilities at Bowers and witnessing key electrical tests before providing delivery to suit our business requirements.”

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Rapid Response Transformer to Wind Tunnel Failure https://www.bowerselec.co.uk/case-studies/rapid-response-transformer/ Thu, 06 Oct 2022 14:09:40 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1476

Rapid Response Transformer to Wind Tunnel Failure

rapid response transformer

Bowers Electricals were contacted by a major customer over a failure of their Ferranti 20MVA 33kV to 11kV transformer at the end of January 2019.

The transformer powered one of the largest wind tunnels in the UK. Being manufactured in 1971 it had served them well, but unfortunately had suffered a catastrophic internal failure. The customer had planned to use the wind tunnel extensively and would be losing revenue each day it was out of action so a rapid response transformer was needed.

Bowers initially looked at considerations to dismantle and return the transformer to their Heanor facility for rewind and repair but then looked at alternative supply of a replacement on an urgent basis.

The typical manufacture of a new transformer of this type would be on a lead time of 26-30 weeks. However, Bowers were able to leverage its strategic partnerships and secure a suitable unit from one of its international suppliers. The transformer was very quickly identified and confirmed by the Bowers technical team to be a suitable size and rating to replace the failed unit – once this was done it was all systems go to get this project running and the rapid response transformer in place.

rapid response transformer

The order to remove the failed transformer, and supply and install the new one was placed under an NEC3 short-form contract with Bowers Electricals undertaking the CDM Co-ordinator, Principle Designer and Principal Contractor roles. The contract was complimented with a requirement for a substantial Neutral Earthing Resistor, Remote Tap changer Control Cabinet (RTCC) and extensive Earthing system upgrades.

Site works were predominantly conducted by the Bowers sister company Electrical Power Engineering Services Ltd (EPES), part of the Bowers Group of Companies. The unit was supplied to the UK within 8 weeks and Bowers oversaw all logistical elements to get it, and the ancillaries delivered to the site.

The old transformer had been removed and site preparations were completed before the arrival of the new transformer. Site excavation works to expose the supply cables for jointing, amendments to the concrete plinth base and preliminary wiring of the RTCC were all done in advance to keep the program on track. Bowers Electricals Ltd then arranged for the offloading via 100 Tonne crane and installation within the compound. The unit was erected, assembled, oil filled and processed before testing and commissioning within the strict EHS and site procedures.

From the first telephone conversation on 31st January 2019 the entire project including the removal of the redundant failed unit, supply and installation of the replacement was completed, commissioned and handed to the client on 14th May 2019 – 103 Calendar days.

Got a similar project? Enquire now.

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Bowers support large National Grid Contract https://www.bowerselec.co.uk/case-studies/bowers-breaks-new-ground-to-support-national-grid-contract/ Thu, 06 Oct 2022 14:08:48 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1475

Bowers support large National Grid Contract

large transformer for national grid contract
large transformer for national grid contract

Bowers Electricals stretched to new capacities recently to deliver one of the largest transformers we have provided, a 25000 kVA 11000/35000 volts at no load, 8% impedance ONAN cooled, Eco-design Transformer for National Grid Contract.

Our end client had tendered and won a National Grid, Short Term Operating Reserve (STOR) contract.

This means at certain times of the day; the National Grid require access to sources of extra power in the form of either increased generation or demand reduction.

Electricity cannot be stored in large amounts, so the supply needs to be balanced with demand on a second by second basis. However, there can be times when unexpected events occur such as generator faults or excessive demand. In order to mitigate these events, National Grid requires either additional generation to run as back up, or a reduction in electricity demand to ensure the system remains balanced.

Short Term Operating Reserve (STOR) is a service which customers (service providers) can provide to National Grid to deliver either a specific level of power from their generators or a reduction of demand.

The service is limited to the timings that are agreed upon in the contract. Such timings are known as the “Availability Windows” which are the periods where the provider is obliged to deliver the specified power. This is generally carried out via electronic instructions from National Grid to the provider.

Bowers Electricals were employed to provide the transformer and associated equipment for our client to deliver their requirements under the STOR contract. The main transformer weighing 40 Tonnes was over the normal 30T lifting capacity. The high current demand during factory acceptance testing needed enhancements to our test facility and extra generation brought in. As Bowers manufactured and tested the transformer at our factory in Heanor they have the capabilities to offer such bespoke solutions. Bowers site facilities include substantial workshops within a 3-acre site, offering rewind facilities, assembly areas, machine shops, several specialist test bays & drying ovens.  All workshops have large crane capacities and the large Transformer overhauling bay has a specialist de-tanking bay, integral oil storage tanks for new/reclaimed and redundant oil, a large drying oven and a generator supplied Transformer Test bay for routine, specialist & witness testing.

Once completed the equipment was despatched from the factory and Bowers undertook the full site installation works; completion is done on time to the required schedule and following all necessary health and safety requirements.

 

Enquire about our Power Transformers here

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Llancayo Solar Farm 5MW, 11kV Grid Connection https://www.bowerselec.co.uk/case-studies/llancayo-solar-farm-5mw-11kv-grid-connection/ Thu, 06 Oct 2022 14:07:50 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1474

Llancayo Solar Farm 5MW, 11kV Grid Connection

transformer for a solar farm

For this project, the end client had an urgent requirement to deliver a large scale project (5MW) in a very short space of time.

Bowers supplied 4 off 1250KVA 415/11500v at no load, 3ph/ 50hz ONAN Dyn11 Copper Windings, Eco Design Dyn11 Transformers and 11000/3/50 switchboard comprising of 4 CE2-T2 200ampVIP300 protected circuit breakers and 1 off 630amp busbar end cable box.

The UK government had given notification of a reduction of the Feed-In Tariffs (FIT) for Photovoltaic systems above 50kW during the Fast Track review. The client had an issue sourcing an experienced EPC contractor that would commit to finishing the project before the required deadlines. Smarter Energy Solutions (SES) sought to provide EPC (Engineering, Procurement and Construction) roles for the project.

 

 

As a sub-contractor, Bowers Electricals conducted an initial site visit and consequently followed with employing SES fast track project evaluation and reporting techniques.

This would enable the client to not only feel comfortable that the project would be delivered but that it would be constructed in a way that would maximise output, re-use materials where possible and be sympathetic to surroundings and local heritage.

Just as well this was undertaken as one notable constraint on the project was that a suspected Roman Temple was buried under a large portion of the project site; this was later confirmed during the build. Liaising with the local archaeologists of the Monmouth council was a key part of the project. This was to ensure that the temple would remain preserved, the location recorded before it was recovered and the installation continues without impact on the history beneath everyone’s feet.

Bowers Electricals were employed not only to provide the equipment but also install all the transformers, switchgear and associated HV Cabling and earthing arrangements.

Several weeks of work on-site, supported by the Heanor facility and its staff were conducted without incident. Despite all the delays associated with the historical excavation the project was completed on time and met the required deadlines required of the end customer.

Enquire about our Transformers

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Witches Solar Farm 6MW, 69kV Grid Connection https://www.bowerselec.co.uk/case-studies/witches-solar-farm-6mw-69kv-grid-connection/ Thu, 06 Oct 2022 14:06:21 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1473

Witches Solar Farm 6MW, 69kV Grid Connection

Witches Solar Farm transformer

Bowers Electricals Ltd were employed by Smarter Energy Services to supply the electrical equipment for a greenfield Solar Farm at Weaven Barn Hoarwithy, Herefordshire, England.

Bowers drew on its in-house technical expertise to specify the overall project and then draw upon its extensive supply chain to source a multitude of complex bespoke items.

Due to the time, critical nature of the site and the deadlines of the end client the equipment was all on the critical path and this led to detailed project management, close control over the logistics and extensive interactions with the other contractors involved.

Equipment manufactured and supplied:

• 1 off 6MVA 69kV to 11kV Outdoor oil cooled Transformer.
• 4 off Merlin Gerin CE2-T12 11kV 200amp Circuit Breakers complete with VIP300 protection.
• 1 off Alstom Visax 11kV Circuit breaker complete with metering, VT and G59 protection.
• 1 off Relays and control protection panel
• 1 Neutral Earthing Resistor
• 1 off 110-volt battery tripping unit to Western Power Distribution Specification.
• 1 off 75kVA 280 volts to 415 volts Auto Transformer for auxiliary supply.

Have a similar project?

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Bespoke transformer tackles power outage problem https://www.bowerselec.co.uk/case-studies/bespoke-transformer-tackles-power-outage-problem/ Thu, 06 Oct 2022 13:58:55 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1472

Bespoke transformer tackles power outage problem

bespoke transformer for international charity

An international charity is saving thousands of pounds a year after Bowers Electricals helped solve serious problems with its power supplies in Africa.

The Watch Tower Bible and Tract Society of Britain hailed Bowers’ service as “impressive” and “excellent” after the team helped to tackle voltage stability issues at the charity’s printing premises in Nigeria.

bespoke transformer for international charity

The site, which was operated by diesel generators for more than 20 years before being connected to a 33kv power supply in 2009 to save money, was experiencing regular drops in supply, causing the printing machinery to cut out – and disrupting operations every week.

Bowers’ in-house team of designers designed and manufactured a bespoke 2500kVA transformer for Watch Tower, with the capability to stabilise the incoming voltage via a sophisticated on-load tap changer and boost the power by up to 40%. Steve Abbott, the charity’s UK-based purchasing manager, said he’d been impressed by Bowers’ approach. “Our requirement for an exceptionally large 40% boost capacity, along with some special tap changer control features, called for a special set of functional tests and we were particularly impressed with the team’s willingness to allow our engineers to work alongside Bowers’ engineering staff in performing tests to our satisfaction at the electrical test facility.”

Right from the outset Bowers’ engineering team showed excellent flexibility in accommodating our specific technical requirements in a manner that proved to be well-engineered while at all times practical and friendly. Bowers’ sales, engineering and production teams showed genuine interest in making sure that the equipment supplied would perform to meet all requirements on site and we could not have asked for more than that

Steve Abbott
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The bespoke transformer was manufactured at Bowers electricals’ headquarters in Derbyshire, where the long-running family business specialises in bespoke and standard energy-saving power and distribution units that reduce losses to cut carbon emissions and electricity bills.

Established in 1947, and managed day to day by the Bowers family, the business sends its products across the world, as well as powering a greener Great Britain with a new ecodesign range that uses the latest in technological advances and materials to offer the greatest savings to date.

Michael Bowers, the managing director of the award-winning company, said: “We’ve prided ourselves on being at the forefront of energy-saving for many years and demand for our products is at an all-time high thanks to an ever-increasing desire to cut carbon emissions. one of our assets is the in-house capability to design and build bespoke solutions for situations just like Watch towers. I’m thrilled that our standards of customer service and attention to detail have been recognised – even when dealing with a client 5,000 miles away.”

Need a bespoke transformer? Enquire now

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Bowers help create zero carbon farm and £200k income. https://www.bowerselec.co.uk/case-studies/farmer-enlists-bowers-to-help-create-zero-carbon-farm-and-200k-income/ Thu, 06 Oct 2022 13:55:36 +0000 http://bowers-electrical.testing.pm/?post_type=case-studies&p=1471

Bowers help create zero carbon farm and £200k income

Zero carbon farm

A Farmer who turned to Bowers Electricals to reduce his electricity bills has described the move as one of his “best decisions ever” after seeing a return of £200,000 a year and the creation of a zero carbon farm.

Andy White, who runs a pig farm near Grantham in Lincolnshire, commissioned Bowers to install a wind turbine which is producing enough energy to not only power his 600-acre business, but two neighbouring villages.

The turbine, which was part of an £800,000 investment by the green-thinking farmer, has been generating 830,000kWh a year since its installation at Frinkley Farm in February 2012.

Thanks to the Bowers transformer and switchgear that it was commissioned alongside, Mr White can sell the electricity he generates back to the grid at 26p per unit, under feed-in tariff rules.

Charged with producing 11,000 pigs a year for Morrison’s supermarkets, and with a herd of 450 sows to maintain, Frinkley Farm was racking up monthly electricity bills of £3,000 before Andy turned to renewable energies. Now he spends just £300 a month keeping his herd warm and believes he has created the UK’s first zero-carbon pig farm.

It was an easy process once we had the planners on side and they understood the wider benefits. Bowers did a great job. Everything has been good and went smoothly and I think it’s been one of the best decisions we’ve ever made.

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Michael Bowers, CEO of Bowers Electricals, added: “We were faced with very tight time constraints on this project and because of the different elements it was quite a complex job but the team ensured everything went according to plan and it was a great scheme for us to project manage. Our work has not only made a real impact on Andy’s bills but on the environment, which is a win-win result.”

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Luxury yacht builder hails Bowers as “fantastic” https://www.bowerselec.co.uk/case-studies/luxury-yacht-builder-hails-bowers-as-fantastic/ Wed, 17 Aug 2022 14:50:22 +0000 http://bowers-electrical.localhost/?post_type=case-studies&p=226

Luxury yacht builder hails Bowers as “fantastic”

fairline boats, luxury yacht builders

The makers of one of the world’s most luxurious yacht brands have hailed the Bowers Group as “fantastic” following a major revamp of their business.

Fairline Boats, who make a range of high-end motor yachts, brought Bowers in when changes in their manufacturing process and an expansion of the business called for a new power supply at their main factory.

Bowers Electricals carried out the contract, which included the supply and installation of a new Bowers distribution transformer at Fairline’s base in Corby, Northamptonshire.

The companies worked alongside the local distribution network operator (DNO) to arrange for a new HV connection and all the contestable and non-contestable works.

During the project, a new DNO substation base was built, along with two GRP enclosures which were kitted out with metering equipment and bespoke high voltage switchgear.

Key to the whole scheme was a new 11kV to 433V distribution transformer, designed and built by Bowers’ highly skilled engi­neers to BSEN60076 standards at their Derby headquarters. This energy-efficient and compact steel-core transformer – chosen for the job because of its low losses – has been housed in a specially-constructed substation on the perimeter of the factory site and has already begun reducing the business’s carbon footprint and generating electricity savings.

Fairline’s Senior Project Engineer, John Husk, explained why Bowers was brought in: “We have three factories in Corby that were built in the 1980s and we decided to bring about a major change to the way we manufacture the boats so that now, one (factory) is used for the furnishings, another for the moulding – the wet processes, liquid resins and white gel finishes and so on – and the third factory is where the finishing takes place,” he said.

This physical change has made a huge difference to the way we operate and, as a result, we had to upgrade the power and utilities at two of the three factories. Because of the increase in electrical demand we needed a transformer and this was how Bowers came to play their part. They were brilliant – fantastic contractors. Everything was done in a timely way, their communication was good and the final install was excellent.

John Husk
Senior Project Engineer, Fairline Boats
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The Bowers Projects team also arranged all the civil and building works, wayleaves and project coordination, as well as taking care of all the necessary Methods and Risk Assessments and Health and Safety paper­work.

Michael Bowers, Managing Director of the Bowers Group, said: “I was very pleased that we were able to supply this equipment and carry out the work for Fairline Boats. My family owned a Fairline 34 some years ago and we have many happy memories of that time. To visit the factory and see the designs for new models and to be able to watch these fabulous boats being built was quite inspirational.

“From a business point of view, it also gave me great pleasure to see another British manufacturer expanding in the same way that we are. “We wish Fairline Boats all the very best with their new range of products and all their future developments.”

Need a transformer for a similar project?

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