Project Spotlight: 125A Secondary Power Supply Installation

Lyons Electrical was appointed by one of our valued clients to deliver a new 125A secondary power supply installation to an existing Motor Control Centre, helping to provide a more resilient electrical supply for the remaining infrastructure serving the building.

Although the original production line had been decommissioned, the existing MCC continued to supply essential services across the facility, including lighting, small power and ancillary equipment. This made the reliability of the electrical distribution network critical to the ongoing operation, safety and functionality of the site.

Industrial Power Distribution Works in a Live Manufacturing Environment

The project involved the installation of approximately 210 metres of 70mm² SWA power cable, routed from an existing substation, through two live stock preparation facilities and across an elevated pipe gantry, before terminating within a separate substation.

Working within a live operational manufacturing environment required detailed planning, close coordination with the client and careful execution from our experienced industrial electrical team. Every stage of the installation was planned to ensure the works could be completed safely, efficiently and without unnecessary disruption to day-to-day operations.

As part of the project, Lyons Electrical also installed a new 125A rotary isolator and a three-phase to three-phase and neutral transformer, creating a neutral where the existing MCC supply was previously neutral-free.

Scope of Works

The project included:

✔ Installation of approximately 210 metres of 70mm² SWA power cable and associated earth conductor

✔ Installation of 150mm heavy-duty galvanised cable ladder, bespoke Unistrut support systems and fabricated steelwork throughout the stock preparation facilities and across the elevated pipe gantry

✔ Integration of the new cable containment system with the client’s existing electrical infrastructure

✔ Removal of the existing MCC100 bus duct, fabrication and installation of a new aluminium gland plate, followed by reinstatement of the bus duct after completion of the new supply installation

✔ Installation of a 125A rotary isolator and three-phase to three-phase and neutral transformer

✔ Modifications within both HV and LV substations, including cable glanding, terminations and associated mechanical works

✔ Complex three-stage cable pulling operation using cable winches, rollers, scaffold access and MEWPs to safely route the new supply through challenging areas

✔ Full inspection, testing, commissioning and NICEIC certification

Delivering Complex Industrial Electrical Installations Safely

Projects of this nature demonstrate that industrial electrical installations involve far more than simply installing cables. They require detailed engineering knowledge, careful planning, accurate cable routing, robust containment, safe working practices and a skilled electrical team capable of operating within live industrial environments.

From substation modifications and MCC supply works to cable containment, transformer installation and final commissioning, every stage needed to be delivered with precision.

A great effort from everyone involved in successfully completing another technically demanding industrial electrical project safely, on programme and to the high standards we strive to achieve.

Industrial Electrical Contractors for Power, Distribution and Infrastructure Projects

Lyons Electrical supports clients across Kent, London and the South East with professional industrial electrical installations, power distribution projects, HV and LV works, electrical infrastructure upgrades, testing, commissioning and NICEIC-certified electrical contracting.

If you are planning an industrial power, distribution or infrastructure project, our team would be happy to discuss how Lyons Electrical can support your next installation.