Regular power interruptions and other problems at Bookham’s optical semi-conductor facility was the driving force behind a major upgrade to the low and high voltage infrastructure undertaken by ABB Power Technologies.
Regular power interruptions, brown-outs and harmonic distortions were affecting the production of semi-conductor wafers and the crystal growth process vital to the efficient operation of the Bookham plant at Caswell, near Northampton.
The major electrical systems infrastructure upgrade project, worth over £2 million, was project managed by Ove Arup working with Hoare Lea Consulting Engineers and ABB as principal contractor.
Bookham is a global provider in the design, manufacture and marketing of optical and RF components, modules and subsystems. The company’s products are used in a variety of applications and industries including telecoms, datacoms, aerospace and defence.
The company’s optical semi-conductor facility at Caswell covers both research and development and production.
POWER PROBLEMS
Hoare Lea Consulting Engineers assisted Bookham in analysing the existing infrastructure and develop an outline design to improve power quality and supply. It was vital to avoid any disruption to the key production operations.
Among the challenges to be addressed were the fact that the site has Grade 1 listed buildings in a rural location and that the site is tightly licensed by the Environment Agency because of the prevalence of toxic chemicals and gases.
Bookham had also set firm demands for the power quality required, in particular there were strict limitations on the damaging harmonics that could circulate on its network.
INNOVATIVE AND SUSTAINABLE
ABB Power Technologies’ contract covered the design, build and installation of the new electrical infrastructure requiring it to act as principal contractor on the project. It co-ordinated all the work from its Rugby office.
The work included the design and build of a number of substations, 11kV incomer, generators, low voltage circuits and the high voltage network. The high voltage system was designed to provide diverse routes with semi automatic open point switching to improve the resilience of the network. Substations are modular in design and provide space to allow for future growth. Transformers are standard output, cast resin construction, have low impedance characteristics and include options for forced cooling.
Modular low voltage switchgear was selected to provide the best performance, safe maintenance and easy future upgrading.
Packaged generator sets with low fuel consumption, and fitted with low sub-transient reactance alternators to improve power quality, were also provided.
The result has been a complete new high and low voltage network designed, installed and commissioned on a challenging site without any significant disruption to existing operations. This includes the seamless integration of 2.5MW of normal and stand-by power in existing hazardous areas together with extensive modification of the existing distribution system within the plant.
A strong culture of innovation and sustainability has pervaded the project with a strong focus on an extended lifecycle, energy efficiency and minimal environmental impact. The project was completed in two phases and was chosen as the Building Services Awards 2004 Project of the Year.