Case Study // Project Overview
BW Industries
BW Industries Ltd is one of the leading steel manufacturing businesses in the North of England, operating out of the Carnaby Industrial Estate in the heart of East Yorkshire since 1974. Their 114,000 square foot production facility uses some of the most advanced machinery available in this industry. However, machinery with this level of power and output comes at a cost in the form of extreme levels of power usage to operate.
The expansive steel roof spanning six adjacent warehouses provided ample space for a system large enough to make a significant impact on power consumption, along with an ideal surface for panel installation.
Challenges
The large scale of the system required extremely long cable runs to connect the panels to the inverter, ultimately totalling over 20 kilometres of cable. This presented design challenges, as our design team needed to maximize efficiency by fitting the maximum number of panels on the roof to achieve the highest possible voltage. Also, to ensure minimal power loss and optimise the energy delivered to the BWIs power system, the design demanded a carefully engineered power distribution layout which is not easy to create at this size.
We delivered a turnkey solution for BWI using our own builders to design and construct the LV Substation, while working alongside Northern Power Grid Engineers. Additionally, we repaired damaged roof sections that couldn’t initially support the weight of the panels. Our electrical engineers fully upgraded the LV switchboard to accommodate the solar PV system and provided spare circuits, future-proofing the site for potential expansions.
Given the size of the roof, a large amount skylights had to be considered during both the design and installation phases. Our installation team successfully mounted both long and short rail systems across these skylights, prioritizing safety at every step. With the added risks posed by roof openings, the team took extra precautions, including wearing harnesses and using fall protection equipment throughout the project.
Before starting installation, we developed comprehensive rescue plans to ensure the crew was fully prepared to respond quickly and safely in any emergency. Designated safety officers from the factory staff were appointed to oversee all safety protocols on-site. These officers conducted regular inspections, monitored compliance, and acted as the first point of contact in the event of any hazards.
To facilitate seamless communication, we established a dedicated WhatsApp group for the project. This allowed our team to remain in constant contact with each other and the factory’s management, enabling real-time updates on progress and addressing any safety concerns as they arose. This instant communication channel proved invaluable for coordinating activities, notifying team members of changing conditions, and maintaining a smooth, secure workflow.
KEY STATS
PV system size: 1.325MWp
Number of panels: 2,226
Annual kWh generation: 1.16GWh
