Elmsall Way Inverter Rooms

Dual Inverter Solution for Complex Industrial Site

Client Brief

As part of a large multi-roof Solar project, we needed to build two new inverter buildings. The challenge was significant:  with one location presenting what appeared to be an insurmountable engineering obstacle, and the other needing some innovative engineering thinking.

Project Overview

Each solution required distinctly different engineering approaches to overcome site-specific challenges. Both installations required seamless integration with the existing PV systems, site infrastructures (both new & old), and site operations.

Elevated Inverter Room (Building 1)

The only appropriate area for the first inverter room was strategically positioned near the cable riser point to maintain optimal system efficiency. However, the initial site investigation revealed extensive high-voltage service cables buried directly beneath the proposed building location. These cables formed a massive network of critical infrastructure that could not be disturbed without causing significant operational disruption to the entire facility.

• Site investigation and underground utility mapping using comprehensive CAT scanning equipment identified the exact positioning of buried HV cables.
• Vacuum excavations to protect underground cables
• Custom steel structures on stilts were designed to span underground infrastructure without disturbance.
• Bespoke steel framework design and fabrication with concrete pad foundations were strategically positioned between cable runs.
• Integration of a new Sub mains system distribution plant room
• Fire walls between the inverter room and the new electrical plant room
• Integrated access solutions with purpose-built gantry walkways and stairs.
• Weather-resistant cladding with integrated ventilation systems for optimal inverter operating conditions.

Ground-Level Inverter Room (Building 2)

• Conventional ground-level construction directly onto a bespoke slab, complete with underground cable ducting system.
• Location positioned to allow entry to the building and not block the loading bays of the facility
• Louvred profile cladding for thermal management and airflow optimisation.
• Streamlined construction processes
• Construction of a bespoke and complex structural cable ladder system.

System Integration

• Both inverter rooms were designed to accommodate multiple inverters and associated electrical equipment.
• Proximity to cable riser points is maintained for efficient PV system connection.
• All installations are compliant with electrical safety and access requirements.

Project Coordination and Delivery

We coordinated all technical aspects between multiple disciplines and external contractors with precise coordination between structural design teams, steel fabricators, and cladding specialists.

Regular on-site coordination ensured works progressed as planned with minimal disruption to daily operations. The location constraints, bounded on three sides by existing buildings, required careful sequencing to maintain access to loading bays throughout construction.

The only significant constraint was working around the existing underground infrastructure, which was successfully managed through our elevated construction approach.

All electrical integration and commissioning were completed as part of the broader PV installation project, which included membrane over-roof work and complete system integration across multiple roof sections.

The Result

The project successfully delivered two fully operational inverter rooms serving separate PV installations, demonstrating our problem-solving capability when faced with complex industrial constraints. The solution preserved existing infrastructure while delivering optimal technical performance within the original timeline and budget.

The elevated inverter room showcases our engineering expertise in developing innovative solutions that work within real-world constraints.

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