Control and Power Case Studies
Control & Power Systems has successfully completed projects for customers across the UK and overseas, designing, manufacturing and commissioning bespoke solutions for organisations of all sizes.
Our customers include private and public sector organisations across a range of sectors, including hospitals, prisons, water authorities, data centres, utility companies, telecoms industry businesses, banks, commercial premises and industrial businesses. Whatever your requirements, you can come to us in the confidence we have the knowledge, expertise and hands on experience required to deliver on your project. Here are some examples of our previous works:
HMRC Washington
The remit was to upgrade the three standby generator local control panels and the main control panel. The existing system was an old and obsolete Petbow system which controlled the three 11kv generators which provided emergency power to the HMRC site and also allowed for the generators to operate in parallel with the local grid supply.
CPS remit was to replace all the controls, we proposed a new design utilising the latest technology using ComAp controllers. We manufactured direct replacement panels for the local generator controls ,which enables our technicians to replace each panel and install the new panels and minimise the time that each generator was off line. The process was to leave at least one generator operational at all times. The main control panel was replaced over a weekend to minimise the downtime. The whole replacement works was completed with the new system fully tested and commissioned and handed over to the client within 2 weeks.
Emergency Repair and Upgrade for Scottish Water Turbine System
Our customer, a renewable energy operator in the highlands of Scotland, experienced a breakdown on a critical water turbine system supplied in 2015. The panel failure threatened their income stream, sustainability efforts, and the smooth operation of their solar, hydro, and generator microgrid.
CPS was called in during this emergency to restore the system and future-proof its operation, facing a number of challenges;
• The breakdown severely impacted the water turbine’s ability to generate income, requiring expedited repairs.
• The site, located in the rugged and remote Northwest Scotland, presented logistical challenges.
• The team faced a mix of extreme weather wind, rain, sunshine, and snow over the four-day operation.
CPS mobilised quickly to resolve the situation:
Rapid Response:
Within a day, we sourced the required parts and travelled 10 hours to reach the remote site.
Our team worked tirelessly over two days to install and repair components, ensuring the turbine and microgrid were operational.
Upgraded System:
Supplied and fitted a new breaker to bring the system back online.
Installed a new controller (Intelligeneo 6000) and upgraded the panel with a ComAp Microgrid solution to ensure seamless operation of solar, hydro, and generator systems.
Intelligent Design:
Integrated controls to prevent the generator from switching off during peak demand, improving reliability and efficiency.
The system was successfully restored and enhanced, minimising downtime and restoring the income stream from the water turbine. Sustainability goals were supported with robust controls for the hybrid energy system.
West Suffolk Hospital – Bury St Edmonds
CPS were the preferred supply to the trust for the new generator & LV system after many years of working with them on an older standby generator system.
The remit was to design and manufacture a standby generator control system that would allow for parallel operation with the grid supply and also to provide local / remote monitoring of the system.
CPS carried out the field wiring terminations and SAT / commissioning for the complete project.
Switchboard system for Scottish Salmon Hatchery
When a significant salmon hatchery on the northwest coast of Scotland began a programme of expansion, we were asked, via a contractor, to supply the new switchboard infrastructure.
The project was completed in two phases.
Phase 1:
Year: 2023
Switchboard: 6300Amp rated Form 4 Type 6 Mains switchboard
Components:
6300amp mains/generator Air Circuit Breakers (ACBs)
DSE8660 mains synchronising controls complete with G99 compliance
26 Feeder ACB or Moulded Case Circuit Breakers (MCCBs)
Process: The system was built and wired at CPS. Due to the panel's length (over 17m), it was shipped to the site in Scotland in ten sections, where CPS engineers spent several days installing and rejoining the new system.
The customer was impressed with the build quality and the expertise of our onsite engineering team, leading them to invite us back for the second phase.
Phase 2:
Year: 2024
Switchboard: 6300Amp Form 4 Type 6 Generator synchronising switchboard
Components:
Four 2500 Amp Generator Synchronising ACBs
6300Amp feeder ACB
Load bank connection ACB
Process:
The system, due to its size (7m in length), was shipped in three sections. CPS engineers once again spent several days installing and rejoining the second phase.
Both phases were successfully completed, with the systems being custom-built, shipped, and installed efficiently by the CPS team, meeting the customer's needs and earning their satisfaction.
Scarborough Hospital Phase 2 LV Mains Control Upgrade
Following the successful completion of Phase One, we were appointed to design and install a new ComAp-based mains control system for Scarborough Hospital. The upgraded system provides fully automatic and manual control of the LV networks across the West, Central, and North substations.
The hospital’s HV generators remain the primary source of backup power, with the LV generator acting as a secondary supply that only starts during a mains failure if the HV generators do not come online within a set timeframe.
To support the new control strategy, each substation received two mains control panels, one for the ‘A’ side and one for the ‘B’ side, along with remote I/O panels to minimise cabling between the RMUs and the control equipment.
System resilience was a key part of the design. Each ‘A’ mains panel includes a ComAp IM1010 mains controller and IM1010 bus-tie breaker (BTB) controller, providing automatic transfer functionality with its corresponding ‘B’ mains panel in the event of a supply failure.
We also upgraded the North Sub LV generator panel, replacing the existing DSE8620 with a new ComAp IG1000 controller. This enables seamless synchronisation to either the LV ‘A’ or LV ‘B’ mains supply.
The existing two local generators mounted at Central sub also had their DSE control panels retrofitted with ComAp IG1000s.
The control system was programmed using ComAp’s dedicated applications:
• MCB for supervising and controlling incoming LV mains circuit breakers
• BTB for monitoring both sides of each bus-tie and controlling BTBs under all operating scenarios
• MINT for managing the generator’s synchronising circuit breaker and enabling synchronisation to both mains sources
Each North Sub mains panel also includes a ComAp MainsPro utility protection relay, providing G99 protection and ensuring safe de-coupling between the mains and generator supplies.
A ComAp IV18 G2 18” touchscreen HMI was installed to give the hospital a live, sitewide overview of both the HV and LV systems. Communication between the HMI and all controllers is achieved over a high-resilience fibre-optic ring network with Ethernet-to-fibre converters in each control panel.
Chemical Engineering Organisation
Our customer is an international chemical engineering organisation who were the victims of a weekend break-in. The thieves stole the copper from within the GRP external unit which housed the main distribution LV Switchboard. The LV Switchboard was damaged beyond repair and as a result mains power could no longer be supplied to a factory unit which was forced to be temporarily closed down; production was moved to a difference part of the site until a solution could be sourced.
The customer needed a solution fast, so that their insurance company could progress the claim, a replacement unit installed, and the factory could resume normal production.
Within 24 hours of the call, CPS had completed a site inspection. A modernised replacement unit including a main LV Switchboard, 3200 Amp LV mains incomer and distribution switchboard with power factor correction was proposed. The insurance company was able to process the claim and the replacement unit was ordered.
With mains power reconnected, our client was able to reinstate production to the unit. CPS provided the complete service, from site survey through to installation, ensuring the process was seamless and quick.
• Within 24 hours the customer had received a site survey, and a solution has been proposed and agreed.
• CPS’ rapid response meant that mains power to be returned to the unit and production could be resumed.
• An updated, replacement system was provided, getting the customer back online and futureproofing the business.
• The equipment is serviced regularly by the CPS team to ensure optimum performance.
NHS Trust Hospital
As part of a modernisation project, CPS was tasked with replacing new mains control systems for three new generators for a major NHS Trust Hospital. The customer had 3 existing generators which were to be replaced with three new generators.
Along with the new mains control system which had to be wired into the existing switchgear, we were also asked to supply a new generator synchronising LV distribution switchboard and accompanying dual mains control system.
Following an initial site survey to assess the existing equipment we modified the existing hospital main switchboard controls and supplied a 2000A quick connect temporary generator connection panel. This allowed the hospital to connect to temporary back up generator power whilst the project was being completed.
We then designed and manufactured a new 4000Amp Generator Synchronising Switchboard and new Dual Mains DSE8660 Mains Control panel.
The team positioned and installed the switchboard and mains control panel and terminated all new site control cables. The existing hospital switchboard was modified to accept the new mains control panel. Finally, the team completed a full onsite commissioning of the system.
Utilising DSE 8660MKII controllers, the new power management system ensures that the critical site supply is completely secure via a dual mains supply and up to 3 diesel back-up generators. Complex control logic makes testing easy with just the flick of a switch.
I just wanted to say a massive thank you to all of your team for a great job well done. Your panels are great and the help you gave the Trust with the controls has been first class!! I have had nothing but glowing feedback from the NHS which is fantastic. Needless to say, I will send all my panel building and controls works your way.
Envigo Research Centre – Eye Suffolk
Control and Power Systems Ltd were approached by the client following several control issues and break downs within their three Generator synchronising control system that supported research blocks. CPS Ltd attended site and completed an initial survey of the generator control system at the Envigo Research Centre in Suffolk, after discussions with the client identifying a number of obsolete equipment it was suggested a complete new control & switching suite of panels would be the most cost effective solution providing the site with a secure back-up power supply.
The new control system was designed and manufactured at our Scarborough facility, fully factory tested prior to shipping to site. CPS Ltd technicians attended site to carryout the works which involved providing a hire generator, removal of the old control and switchgear panels and installation of the new panel suite, before commissioning the new system and training of the onsite engineers.
“I would just like to say how impressed we have been with the work that has been completed. Gary, Paul, and Jack have done a superb job, and have been a pleasure to have on site.”
Envigo Team Leader
Scarborough Hospital Phase One
HV Control System
When a major hospital required a reliable and resilient backup power solution, Control and Power Systems was proud to step in and deliver. Working alongside a leading generator manufacturer, we designed, built, and installed advanced control systems, custom ComAp panels, various monitoring interface panels and HMI overview screen for the Two HV substation switchgear and two high-capacity containerised diesel generators, each providing over a massive 2,500kVA of standby power.
The first phase required us to provide both fully automatic and manual control of the hospital’s new dual high-voltage (HV) ring system.
Working closely with the Main contractor a phased integration was planned, including the use of temporary control panels to ensure the site wasn’t compromised at any stage of the works. We installed a new ComAp-based generator control system which included dedicated control panels and a separate HMI overview display panel on both new systems.
ComAp IG1000 controller supervises the incoming HV mains supply and manages the operation of the associated mains circuit breaker.
A ComAp IM1010 controller controls the bus-tie breaker, enables synchronisation between the generator and mains supplies and provides full Automatic Transfer Switch (ATS) functionality. Switching operations are based on the required control scenarios.
An IV5.2 door mounted display provides local control and system status visibility.
ComAp InteliPro mains protection relay ensures safe disconnection of mains and generator supplies under G99 grid loss or trip conditions.
The ComAp IG1000 generator controllers are programmed with the ‘MINT’ application, enabling control of the generator’s HV synchronising circuit breaker (GCB). This allows synchronisation with either mains supply, as well as with the other generator.
To mitigate the impact of energising the 400/11kV generator transformers, the system is configured to allow generators to start and run with their local circuit breakers already closed. This 'soft mag-up' process gradually energises the transformers, reducing inrush current and its effect on the generator.
A ComAp IV18 G2 18-inch touchscreen display was installed on the HMI panel door to provide a live graphical overview of both the HV and LV systems. Communication with all controllers occurs over Ethernet. Owing to the physical distance between the HV and LV control panels, Ethernet-to-fibre converters and a fibre ring network were used to ensure fast and reliable data transfer.
Despite site delays, our team swiftly deployed an interim generator setup, fully commissioned in under a month which was almost a week ahead of schedule. on this text to edit it.
" Since CPS joined the team, the project took a huge turn in the right direction... we now have the HVLV system fully supporting the hospital. I honestly don’t think we would have achieved this without you.”
Senior Building Services Manager