Overview
We took on the exciting challenge of designing and implementing a comprehensive electric vehicle (EV) private network for a bus garage in Rotherham, Sheffield. This project was a pivotal step in supporting the client’s transition to sustainable transport by installing new EV charging infrastructure to serve their growing fleet.
Scope of work
We designed the electrical network for the site. We navigated the approval process, ensuring that our plans adhered to all regulatory standards and met the client’s operational needs. We established a 2500 A low-voltage (LV) feeder pillar, equipped with a main incoming breaker and 12 outgoing breakers tailored for the chargers. Space was allocated for front and rear access to ensure ease of operation and future maintenance.
Trenching was carried out to install single-core LV cables from the transformer to the new LV feeder pillar. We carefully coordinated with other contractors to handle excavation within the transformer substation footprint and ensured the cables were presented within one metre of the transformer for termination by others.
Low-level containment was installed to route cables throughout the site to the charger locations, ensuring a streamlined and organised cable layout. Twelve 120 kW stand-alone DC floor-mounted chargers were installed on newly constructed concrete foundations. Bollard protection was provided for each charger, with 24 yellow powder-coated bolt-down bollards strategically placed to safeguard the infrastructure.
To facilitate seamless communication between the LV feeder pillar and each charger, we installed CAT6 data cables. These cables were protected in flexible ducting and routed through the proposed containment system.
We witnessed the commissioning of the chargers, conducted by the manufacturer, to ensure they operated at peak efficiency. After energising the system, we handed over a fully operational EV charging network, complete with all necessary testing certificates and documentation.
Challenges and solutions
One of the main challenges of this project was coordinating trenching and cabling works with other contractors responsible for the transformer substation. By maintaining open communication and a proactive approach, we ensured smooth collaboration, avoiding delays and ensuring timely delivery.
Additionally, the compact site layout required meticulous planning to accommodate the feeder pillar and chargers while ensuring easy access for future maintenance.
Outcome
The project was successfully completed on time and to the highest standards, providing the garage with a modern, reliable and scalable EV charging infrastructure. The 12 high-power chargers enable the client to efficiently charge their fleet, aligning with their sustainability goals and reducing their carbon footprint. This project exemplifies CX Energy’s commitment to delivering tailored, innovative solutions that support clients in their journey toward net zero.