Switchboards Replacement Project – Mangere

DESCRIPTION 

The Mangere Wastewater Treatment Plant (WWTP) Switchboards Upgrade project involved the renewal of key low voltage (LV) distribution infrastructure within one of New Zealand’s most critical wastewater facilities. The project was driven by the need to replace aging switchboards approaching end-of-life, improve system reliability, and align with current electrical and safety standards. 

The works were undertaken within a highly constrained brownfield environment, requiring careful planning to manage interfaces with existing plant and maintain operational continuity. The upgrade formed a key component of Watercare’s broader strategy to modernise critical electrical assets across the Mangere site. 

SCOPE 

Actemium’s scope included the design coordination, supply, installation, and commissioning of new LV switchboards and associated infrastructure. Key deliverables included: 

• Detailed design coordination and integration of new switchboards within existing electrical systems 

• Supply and installation of new LV switchboards, including protection, control, and metering equipment 

• Modification and reconfiguration of existing cabling systems to suit new board arrangements 

• Installation of new cable containment, glanding, and termination works 

• Staged changeover and cutover of live electrical systems to minimise operational disruption 

• Implementation of temporary supplies where required to maintain plant uptime during changeovers 

• Testing, commissioning, and energisation of new switchboards in accordance with project requirements 

• Preparation of as-built documentation, test records, and O&M manuals 

All works were delivered within a live treatment plant, requiring robust isolation procedures, detailed shutdown planning, and close coordination with site operations. 

VALUE TO CLIENT 

Actemium delivered significant value to Watercare through the successful upgrade of critical electrical distribution infrastructure, including: 

• Improved Reliability and Resilience: Replacement of aging switchboards reduces risk of failure and enhances long-term operational stability of the plant 

• Seamless Integration: Careful design coordination ensured compatibility with existing systems and minimised rework during installation 

• Minimised Operational Impact: Staged cutovers and temporary supply arrangements enabled uninterrupted plant operation throughout the works 

• Enhanced Safety: Upgraded equipment and protection systems improve electrical safety for both operations and maintenance personnel 

• Future-Ready Infrastructure: The new switchboards provide capacity, flexibility, and maintainability aligned with Watercare’s long-term asset strategy