Dual AVR Control Panel for Leading UK Energy Facility
Sector: Energy & Renewables
Scope: Manufacture of 8-Cubicle Dual Channel AVR Control Suite
Client Type: High-End, Strategic Partnership
Unique Element: HV Busbar Section Manufactured Overseas
The Challenge
We were selected by a strategic partner in the energy and renewables sector to deliver a complex and highly technical build - one of two 8-cubicle Dual Channel Automatic Voltage Regulation (AVR) control panels - for one of the UK’s largest and most efficient Combined Heat & Power (CHP) plants.
The challenge was to replace an existing AVR system within extremely limited on-site space, while integrating equipment sourced internationally and managing high client expectations across multiple stakeholders.
Our Solution
We engineered and manufactured the front section of the AVR suite, which houses all critical control, PLC, and AVR hardware. This was completed in partnership with:
A high-voltage mechanical section
A custom plinth system to manage interface wiring between front and rear sections
Side-mounted field termination points using Rittal proprietary hardware, allowing for seamless installation in tight spatial constraints
Despite the complexities of the installation and equipment origins, we delivered a fully integrated, reliable solution tailored to the exact requirements of the site.
Flexible Manufacturing Expertise
This project showcases our manufacturing versatility, having worked from client-supplied (free-issue) drawings rather than our own designs. It’s a clear demonstration of our ability to deliver to third-party specifications, which is an essential skill when collaborating with Tier 1 suppliers and end users in high-stakes environments.
Key Highlights
Integrated HV and LV control sections, manufactured across two countries
Built for one of the UK’s flagship CHP energy sites
Managed complex spatial, technical, and logistical challenges
Successfully worked to free-issue client designs
The first AVR suite is now complete and ready for deployment. A second identical system is currently in production, with delivery scheduled later this year.