Introduction
Denca provides end to end electrical design, manufacture, and installation services for complex industrial and energy infrastructure projects. We offer extensive experience in modernising legacy electrical systems. We support our customers with integrating new technologies efficiently, safely, and with minimal operational disruption. Our in-house capabilities enable us to deliver fully coordinated solutions that are future-ready, compliant, and built for long-term performance.
The Challenge
On-Site Energy, who specialise in reducing energy costs and carbon emissions for energy intensive manufacturers, identified an opportunity to enhance energy efficiency and reduce carbon emissions through the development of a large-scale solar installation on greenfield land owned by their customer. The 26 hectare solar farm has a peak annual output capability of 18.2MW. It can supply 31% of the customers’ energy demand at the site. Furthermore, it achieves a targeted reduction of approximately 3,500 tonnes of carbon emissions per annum once fully commissioned.
To support this ambition, the site required new, high-capacity LV distribution infrastructure capable of integrating renewable generation while interfacing seamlessly with existing intake and HV switchroom systems. The challenge was to modernise the electrical distribution network to accommodate future energy demands. At the same time the system had to ensure full compliance with grid requirements. Additionally, we had to deliver the installation within a compressed timeline, all without disrupting existing site operations.
The Solution
Denca secured the contract in March 2025. The scope included the design, manufacture, and installation of five 2500A LV Distribution Centres. Denca also provided full site installation services, supporting On-Site Energy as their delivery partner.
Immediate mobilisation enabled works to progress efficiently from March through to project completion in August 2025. We designed and manufactured five new 2500A, 800V LV Distribution Centres. Each unit was housed within newly constructed switch rooms complete with associated building services. To facilitate G99 and G100 grid compliance, two new 110V battery units were installed, alongside third-party SCADA and control panels .
Solnet, a Finnish Solar EPC, supplied and installed the renewable energy infrastructure. This included over 31,000 solar panels connected via approximately 58,000 metres of DC cabling to 48 inverter isolators across the site. Denca’s scope included the installation of approximately 13,000 metres of 800V inverter power cabling in ground trenches. The cabling runs from the distribution centres to the field-mounted inverter isolators. In addition, approximately 800 metres of transformer single-core cabling supports power distribution across the site.
Robust communication solution
Robust communications and monitoring were essential deliverables in the project. Consequently, we installed approximately 9,000 metres of fibre optic cabling to interconnect switch rooms and provide connectivity to 12 perimeter CCTV cameras. All fibre terminations were completed by an approved specialist subcontractor. Full test results were included as part of the handover documentation.
Critical to the project’s success was the careful modification and interfacing with existing panels and cabling within the customers’ intake station and HV switchroom. This ensured seamless integration between new and legacy systems.
The on-site delivery was supported by our dedicated project team. The team included a visiting Project Manager, a working Supervisor, eight electrical installation engineers, and six cable installers. Together they delivered strong coordination, safety, and quality throughout.
“The electrical installation was executed flawlessly, with meticulous attention to detail and full compliance with industry standards. They maintained clear communication throughout the project, met every milestone, and coordinated seamlessly with other contractors on-site. It has been a great experience to have had Colin, Phil and the project team to work alongside on this project.” Jamie Yeates, Site Manager, On-Site Energy Ltd
The Results
The scheme successfully delivered a modern, high-capacity LV distribution infrastructure. The installation enables the effective integration of renewable energy generation. The project also prepared the site for future expansion and evolving energy strategies.
On-Site Energy now benefits from a robust, compliant, and scalable electrical distribution system that supports improved energy efficiency, reduced overhead costs, and long-term sustainability objectives. The installation provides the foundation for the solar farm to deliver up to 31% of the site’s energy requirements, contributing significantly to carbon reduction targets once fully commissioned.
The project was delivered within the agreed programme, with minimal disruption to existing operations, and supported by comprehensive Denca test documentation at final handover reinforcing confidence in system performance, safety, and compliance.