In May 2008 Balfour Beatty Engineering Services working with Carillion Building North commenced work on a 2 year infrastructure upgrade of the Catterick Garrison 11,000 Volt intake and distribution network (11 KV Project) for the Defence Estates and the MOD.
The £10 million project is to replace the predominantly 35mm2 cables around the Garrison, with cables up to 240mm2 along a 22Km route.
The new cables were terminated into 37 Distribution Substations, and there was provision of an additional 15MVA intake Substation within one of the Barracks.
The purpose of the upgrade was to meet the projected 2017 power requirements of the Garrison, due to an anticipated 50% increase in population.
“Adien have been an integral part of the project from the start and the contract would not have been as successful without their involvement. When BBES started to cost the project it was found to be impossible to cost accurately, as the existing service drawings were so out of date and incorrect. To this end Adien scanned and produced drawings of the 10 most difficult areas to ascertain how many services would be encountered, on the back of this information is was possible to cost the project and make it financially viable. Without this information this would not have been possible and the project would not have been viable from the outset.”
Phil Wilkinson – Project Manager, Balfour Beatty Engineering Services Limited
Adien’s involvement in the project
Building on the successful relationship developed across other major building projects undertaken by Carillion Building North within Catterick Garrison, Balfour Beatty Engineering Services commissioned ADIEN, as part of the bid process for the 11 KV Project, to carry out some comparison and evaluation work around the garrison to better understand the risk potential arising from the amount of services on the statutory undertaker records and the actual amount of services around the garrison, consequently 10 areas where selected and surveyed.
As a result of ADIEN’s findings Balfour Beatty Engineering Services made the decision for health, safety and commercial reasons relating to the discrepancies between recorded services and actual services, that the whole 22Km route would be surveyed before the cables were upgraded, the cables were to be up graded by means of open cut, thrust moleing and vacuum excavation in the majority of cases the type of technique used became dependent on the results of the utility survey and subsequent locations and proximity of services.
It was decided early on in the project that ADIEN would survey the route 2 weeks in front of the teams, this allowed for the correct quality assurance checks to take place and appropriate drawings of the route to be produced to adequately assist the installation teams in the safe undertaking of their works.
The Drawings of the proposed routes were produced in 200m linear lengths which formed part of the installation teams permit to break ground / work.
Prior to an installation team commencing work Adien would return to the site and remark the findings of the survey on the ground in 200m length packages.
ADIEN provided the project management team and their supervisors with a pictorial guide of the markings that would be present on the ground, offering clear indication as to service type present so far as is reasonably practicable.
All parties were invited to a workshop at ADIEN’s head office where we demonstrated methods of location utilised and the limitations of the technology and that the median expectation is an 85% success rate.
Upon completion of the survey works to the proposed route our senior supervisor was seconded to the project management team, where his duties included mark up identified services along with support advising on the findings of the surveys.
On completion of installation works and energising of the HV cables, ADIEN returned to site and surveyed the entire 22km route to produce “as installed drawings” as part of the submission and handover documents as required by the Client. This has now given the Client an accurate record of the all services in and around the new HV routes which is a vast improvement on what had previously been held by the MOD at Catterick Garrison.
Benefits to the project
- ADIEN have achieved a 97.4% detection rate over the 22km of the project.
- As part of a risk reduction and costing exercise ADIEN undertook surveys in areas with highly populated services, to confirm and quantify the amount of hand digging and therefore the associated costs to be included within the pre-contract estimate.
- Allowed finite planning of the route to be undertaken so that the number of services encountered was minimised.
- Provided the installation teams with structured information of the hazards to be encountered within the 200m runs covered in the work permits and associated service drawings.
- Production of real time mark outs of the hazards on the ground.
- Improved the planning and implementation of road crossings whilst minimising the time required to carry them out as a result of improved selection of route thus mitigating potential service damage.
- Minimisation of disruption to supply and improving the health and safety offered to third parties and employees by profoundly reducing the amount of conventional excavation that was required.
Success of the project
- Due to the poor quality of information and consequential risk of service interruption experienced in the past on construction projects within the Garrison, both the Garrison Management and Carillion Building Services expressed major concerns that there was a real potential risk of harm to individuals, commercial operations and the military. In the event it is therefore acknowledged by the whole project team that the number of service strikes encountered during the works has been extremely low. This is predominately due to the quality of the survey works and QA procedures undertaken and implemented by ADIEN in support of the professional installation teams carrying out the work, This includes the upfront checking of relevant existing construction and utility drawings and cross referencing with surveys that have been undertaken, to produce an overall master drawing showing all known and previously unknown services.
- In 2009 the project received the ultimate safety recognition of a RoSPA Gold Award for outstanding health and safety procedures and operational excellence.
- In a recent customer satisfaction survey Defence Estates gave a perfect 10 out of 10 for the 11 KV project team at Catterick Garrison.
- The delivery of the 11KV project is a major part of the Catterick Garrison long term development plan, and by ensuring minimal disruption to the operational duties of the MOD and Garrison this has been viewed by Defence Estates as “a very successful project”.
- The project was delivered ahead of programme and within budget.
- The survey works provide an accurate record of the new HV installation and surrounding services for future reference by the MOD and Defence Estates