AIAL Work package 1 for the Eastern Terminal Integration

DESCRIPTION 

Auckland Airport is underway with its biggest redevelopment since the airport opened in 1966, moving forward with a brand-new domestic terminal to be fully integrated into the international terminal. 

Set to open between 2028 and 2029, the new integrated terminal will house domestic and international travel under the same roof for the first time since 1977, via an expansion at the eastern end of the existing international terminal building. 

SCOPE 

(Stage 1: Installation of Substation PC68 Temporary (“Portacom” Building) and Transformer Connections 

Foundation and Structural Works 

Construct foundations and structural elements for the Substation PC68 Temporary (“Portacom” building). 

Earth Grid Installation 

Install earthing conductors and connect to existing and new reinforcing steel. 

Measure and confirm the resistance of each earthing connection to Earth before the concrete pour. 

Record results as per Inspection Test Plan (ITP) and ensure photographic evidence is captured. 

Supply and Install Substation PC68 Temporary 

Deliver and install the Portacom containerized Substation PC68 Temporary on site. 

Complete off-site mechanical, fire suppression, and electrical fit-out, including power, lighting, HVAC, and fire suppression systems. 

Installation of HV and LV Equipment 

Install new HV switchgear, dry-type transformer TX1, LV switchboard, and minor LV panels. 

Coordinate the lifting and movement of equipment with specialist moving tools and inspect upon completion. 

Obtain approval for the Transport Management Plan (TMP) and lifting plan from Hawkins. 

Main Earth Bars Installation 

Install main earth bars and establish connections to equipment, wricon connectors, and main buried connectors. 

Measure and record the resistance of the main earth bar to Earth as per ITP, with photographic evidence. 

Substation PC11 HV Switchgear Isolation 

Isolate and earth Substation PC11 HV Switch CB9, with an approved switching plan from Hawkins. 

11kV Cabling Installation and Termination 

Install and terminate 11kV cabling from Substation PC68 Temporary HV Switch CB1 (K01) to Substation PC11 HV Switch CB9 (K09) along the existing cable ladder. 

Liven, Test, and Commission 11kV Switchgear 

Liven, test, and commission the 11kV switchgear from Substation PC11 HV Switch CB9 (K09). 

Record Switchgear and cabling Site Acceptance Testing (SAT) in the ITP. 

Substation PC68 Temporary Commissioning 

Bring Substation PC68 Temporary into service as a spur from Substation PC11 HV Switch CB9 (K09). 

Further 11kV Cabling and Terminations 

Install and terminate additional 11kV cabling for the following connections: 

Substation PC68 Temporary HV Switch CB6 (K06) to Substation PCJBP1 HV Switch CB7 (K07). 

Substation PC68 Temporary HV Switch CB5 (K05) to Transformer TX1. 

Substation PC68 Temporary HV Switch CB2 (K02) to Transformer TXK. 

Substation PC68 Temporary HV Switch CB3 (K03) to Transformer TXN. 

Substation PC68 Temporary HV Switch CB4 (K04) to Transformer TXL. 

Testing and Commissioning of Transformers 

Liven, test, and commission 11kV cables and transformers connected to Substation PC68 Temporary: 

Transformer TXK via HV Switch CB2 (K02). 

Transformer TXN via HV Switch CB3 (K03). 

Transformer TXL via HV Switch CB4 (K04). 

Confirm transformer rotation during commissioning. 

Stage 2: Permanent Installation of Substation PC68 (Works Yet to Be Performed) 

Earth Grid Installation 

Install earthing conductors for the earth grid and connect to new and existing reinforcing steel. 

Measure and record earthing connection resistance to Earth before concrete pour, with photographic evidence. 

Mechanical and Electrical Fit-Out 

Complete the mechanical and electrical fit-out of the permanent Substation PC68, including power, lighting, and HVAC. 

HV Switchgear Installation 

Install new HV switchgear, Bus Tie, and other minor LV panels. 

Coordinate lifting and movement of equipment with specialist tools and obtain Hawkins’ approval for TMP and lifting plan. 

Main Earth Bars Installation 

Install main earth bars and establish connections to equipment, wricon connectors, and main buried connectors. 

Measure and record resistance as per ITP, with photographic evidence. 

HV Cabling Installation and Commissioning 

Isolate and earth Substation PC11 HV Switch CB19, obtain Hawkins’ approval for the switching plan. 

Install, terminate, liven, test, and commission 11kV cabling from Substation PC68 HV Switch CB1 (K01) to Substation PC11 HV Switch CB19 (K19). 

Stage 3: Integration of Substation PC68 into HV Ring (Works Yet to Be Performed) 

HV Cabling Installation 

Install 11kV cabling from Substation PC68 HV Switch CB13 (K13) to PCIB RMU1. 

Isolation and Earth of Existing Switchgear 

Isolate and earth Substation PC11 HV Switch CB4 (K04), RMU1 PCIB, and Substation PC68 HV Switch CB13 (K13), with an approved switching plan from Hawkins. 

Termination and Testing 

Disconnect existing 11kV cable and terminate new cabling from RMU1 PCIB to Substation PC68 HV Switch CB13 (K13). 

Liven, test, and commission 11kV cabling to integrate Substation PC68 into the HV ring. 

Stage 4: Installation of Substation PC69 and Transformer Transfers (Works Yet to Be Performed) 

Earth Grid Installation 

Install earthing conductors and connect to existing and new reinforcing steel. 

Measure and record earthing connection resistance to Earth before concrete pour, with photographic evidence. 

Mechanical and Electrical Fit-Out 

Complete the mechanical and electrical fit-out of Substation PC69, including power, lighting, HVAC, and Bus Tie installation. 

HV Switchgear and Transformer Installation 

Install new HV switchgear and transfer transformers from Substation PCJBP1 and Substation PC68 Temporary to Substation PC69. 

Coordinate lifting and movement of equipment and obtain TMP and lifting plan approvals from Hawkins. 

HV Cabling Installation and Commissioning 

Isolate and earth Substation PC68 HV Switch CB11 (K11), obtain Hawkins’ approval for the switching plan. 

Install, terminate, liven, and commission 11kV cabling from Substation PC68 HV Switch CB11 (K11) to Substation PC69 HV Switch CB8 (K08). 

Ensure Substation PC69 operates as a spur from Substation PC68 HV Switch CB11 (K11). 

Stage 5: Connection of Substation PC69 to the HV Ring and Final Load Transfers (Works Yet to Be Performed) 

HV Cabling Installation 

Install 11kV cabling from Substation PC69 HV Switch CB5 (K05) to Substation PCWEST HV Switch SW1. 

Install 11kV cabling from Substation PC69 HV Switch CB4 (K04) to Substation PCIB HV Switch K02. 

Isolation and Earth of Existing Switchgear 

Isolate and earth Substation PC69 HV Switch CB5 (K05), Substation PCWEST HV Switch SW1, and Substation PC11 HV Switch CB12 (K12), with an approved switching plan from Hawkins. 

Termination and Commissioning 

Disconnect and remove existing 11kV cable, terminate, connect, liven, and test new 11kV cabling from Substation PC69 to Substation PCWEST and PCIB. 

Confirm transformer rotation and fully commission Substation PC69 as part of the HV ring. 

VALUE TO CLIENT 

This project adds significant value by providing the essential infrastructure that supports Auckland Airport’s ambitious redevelopment plans, aligning with their sustainability goals, and enhancing the overall passenger experience. The use of the Portacom as a temporary substation exemplifies our commitment to innovation and initiative. By outfitting a Portacom building with 11kV switchgear, we ensure a flexible and efficient solution that allows for uninterrupted power supply during the construction phase. This approach not only minimizes disruptions but also showcases our ability to adapt and implement creative solutions in complex environments.