Case Study: National Grid Independence
Client: Tawny Hotel & Hospitality Venue.
Completed: Phase 01 September 2024
Location: Consall, Staffordshire.
System Cost: £580,000
Services Used
- Design
- Ground Works
- Installation
- Maintenance
Extensive Hospitality Venue achieves National Grid Independence.
Objectives
The client wished to achieve self-sufficiency in electricity production for the entire Tawny site, which includes a wedding venue, hotel, and offices.
The primary objectives were twofold: first, to ensure a continuous and reliable power supply for all site facilities, and second, to realise significant long-term savings on power costs.
To achieve this, we designed a comprehensive microgrid system enabling the site to operate independently from the National Grid.
This innovative system includes battery storage, 14 electric vehicle (EV) chargers, and intelligent controls.
We optimised existing generators when necessary, ensuring a reliable power supply and long-term cost savings.
This large project has been divided into two phases of installation; this case study covers stage one. Phase two will involve the addition of solar PV energy.
System Integration Overview
The microgrid system at the Tawny site was designed for optimal efficiency and resource management. The various components, including a 600kW battery storage system and existing generators, were seamlessly integrated.
Details of Phase 0ne:
Generator Control and Efficiency:
- The existing generators have been modified and are now equipped with advanced control systems that optimise their operation for efficiency.
- These generators will now dynamically adjust their output to match the site’s energy demand and battery charging capacity, ensuring they operate at their most efficient levels.
- By synchronising generator output with real-time power needs, fuel consumption is minimised, leading to cost savings and reduced environmental impact.
Bespoke Section Board with Integrated Controls:
- A bespoke section board was custom-designed and manufactured for the project, incorporating control equipment within the panel.
- This custom section board serves as a central hub for monitoring and controlling various elements of the microgrid, enhancing the system’s efficiency and reliability.
Battery Storage and Management:
- The 600kW battery storage system plays a multifaceted role in ensuring a reliable and efficient power supply throughout the day.
- It is programmed to achieve a 100% charge by 11 pm daily, ensuring a robust energy reserve for nighttime.
- Dynamic charging management is employed, where the generators adjust the amount of power sent to charge the battery based on real-time energy consumption, optimising battery use throughout the day and minimising generator usage.
- This efficient battery management also contributes to reduced maintenance costs for the generators.
- The system has been designed to integrate the solar electricity, which will be generated onsite during phase two of the project.
BSS and Section Board Integration
The battery’s use during both day and night ensures a consistent power supply and optimal resource management. With its substantial 600kW capacity (expandable to 1MW), the system provides flexibility, cost savings, and reliability. The inclusion of the bespoke section board enhances the microgrid’s overall control and efficiency, contributing to its successful operation.
Meel Group Teams involved in this project.
- Electrical Engineers: Electrical engineers play a central role in designing and implementing microgrid systems. Their expertise includes power distribution, wiring, and electrical control systems. This team also successfully integrated the bespoke section board.
- Battery Technology Specialists: Experts in battery technology, planning, and management.
- Control Systems Engineers: Control systems engineers were responsible for developing and implementing the intelligent controls that govern the microgrid. Their skills include programming and automation to optimise energy flow and usage.
- Mechanical Engineers: Mechanical engineers were involved in aspects related to the project’s physical infrastructure, such as housing the battery in the shipping container and ensuring proper ventilation and cooling.
- Groundwork and Site Preparation Teams: Groundwork and site preparation teams were responsible for the physical installation of the battery container and the charging infrastructure for electric vehicles. Their skills encompass construction, logistics, and site safety.
- Project Management: Project managers oversaw the coordination of the various teams, timelines, and resources. They ensured that the project proceeded smoothly and met its objectives.
- Design and Planning Specialists: Design and planning specialists created the overall system design, including layout, capacity planning, and future expansion considerations.
- Energy Efficiency Experts: Experts ensure that the microgrid system operates optimally and minimises energy wastage.
Site-Specific Expected Challenges:
The site includes a large hotel, a restaurant, and a wedding venue.
We expected that tailoring the microgrid system to suit the site’s unique requirements and providing an uninterrupted power supply during the works would be a challenge. However, with correct planning and our expertise, we achieved this smoothly.
Integration Complexity: Integrating multiple components, battery storage, existing generators, and electric vehicle chargers while optimising their interaction was a complex task. Ensuring these systems worked seamlessly together posed a challenge.
Future Expansion: Designing the system for future expansion, including the ability to integrate the output generated from a large ground-mounted solar panel field during phase two.
Generator Optimisation: Optimising the operation of existing generators for efficiency and fuel savings was essential. Achieving this while maintaining a consistent power supply for the site was a significant challenge our teams overcame.
Dynamic Battery Management: Managing the batteries to meet varying energy demands throughout the day and night required precise control. We achieved the aim of a 100% charge by 11pm while utilising the battery effectively during daylight hours.
Overcoming an Unexpected Difficulty:
An unexpected difficulty emerged during the project’s initial testing phase. We discovered that the existing generators’ control systems were incompatible with the proposed microgrid controls.
To overcome this challenge, the project team collaborated closely with the generator manufacturer and control system specialists to develop a custom interface that allowed the microgrid controls to communicate effectively with the generators.
This unexpected setback was transformed into an opportunity for innovation, resulting in a more refined and efficient control system that resolved the compatibility issue and enhanced the overall performance of the generators within the microgrid.
By addressing this unexpected difficulty, the project team demonstrated their adaptability and problem-solving skills, ultimately enabling the successful integration of all components.
Health & Safety Requirements and Impact:
Health and Safety considerations played a significant role in the project due to the nature of the work, potentially hazardous equipment, and the need to ensure the safety of both the project personnel and the site occupants.
Several key requirements and impacts were identified:
- Battery Handling Safety: Due to its size and weight, moving and installing the 600kW battery storage system enclosed within a shipping container posed potential risks. To prevent accidents during installation and maintenance, strict adherence to safety protocols was required.
- Electric Vehicle Charging Safety: As part of the installation of 14 electric vehicle (EV) charging points, our safety considerations extended to the charging infrastructure. Proper grounding and electrical safety measures were essential to mitigate electrical hazards.
3. Generator Operation: Ensuring the safe operation of the existing generators was crucial. This involved protocols for fuel handling, exhaust emissions, and generator maintenance to prevent accidents or health risks.
4. Large Cable Installation: Installing large cables for power distribution presented additional safety challenges, including cable handling, termination, and secure installation.
Mitigation Measures:
To address these Health & Safety requirements and mitigate the associated risks, the following measures were implemented:
Specialist Logistics Company: A specialist logistics company was engaged to survey the site and safely lift the battery container into its designated position. This approach minimised the risks associated with moving the heavy container.
Battery Cell Installation: After the container was safely in place, electrical engineers installed the battery cells individually. This systematic approach ensured that the installation of the battery was performed safely and accurately.
Large Cable Handling: Large cables for power distribution were installed with the utmost care. Correct cable handling and securing techniques were employed to prevent accidents or damage during installation.
Safety Training: All personnel involved in the project received comprehensive safety training, including specific training on safely handling batteries, electrical safety around EV chargers, generator operation procedures, and large cable installation protocols.
Personal Protective Equipment (PPE): Workers were required to wear appropriate PPE, such as safety helmets, high-visibility vests, gloves, and safety glasses, to enhance their safety on-site.
Routine Safety Checks: All equipment, including generators and cables, was inspected regularly and maintained to identify and rectify any potential issues promptly.
Emergency Response Plan: An emergency response plan was developed and communicated to all project personnel. This plan included procedures for handling accidents, fires, and other emergency situations.
Environmental Impact Assessment: The project’s environmental impact was assessed to ensure that it complied with environmental regulations, safety standards and reduced waste.
Mitigating risks results
By implementing these comprehensive mitigation measures and adhering to Health & Safety requirements, the project successfully minimised risks, ensuring the safety of the project team and the site occupants.
