Project Kuhawaha – North Island Energy East

DESCRIPTION 

Project Kuhawaha North Island Energy East – Installation of an 11kV Switchboard for the new 30MW Resistive Electrode Boiler. 

The Fonterra Edgecumbe Electrode Boiler Project is a large-scale industrial electrification and decarbonisation initiative involving the delivery of new 11 kV Electrical Infrastructure to support a 30 MW Electrode Boiler facility.  

The project includes the construction of a new high voltage 33kV/11kV intake substation by Horizon Energy and downstream 11kV switchboards, transformers, protection systems, HV cabling, testing, and commissioning by Omexom.  

Delivered through a staged programme by Omexom and overall project coordination by Worley, the project demonstrates specialist capability in complex industrial electrification and brownfield integration while supporting Fonterra’s transition away from fossil fuels, reducing emissions, and improving long-term operational sustainability. 

SCOPE 

Omexom’s Scope of Work covered the following: 

• Assembly, Installation, Testing and Commissioning of the 11kV Schneider PIX Switchboard. 

• Termination of 15 x 1C 630mm2 Cu Incoming Cables to 11kV Switchboard SWB-5501BH 

• Supply and Installation of Cable Containment.  

• Installation and Termination of 12 x 1C 240mm AL Electrode Boiler Feeder cables   

• Installation, Termination and Commissioning of 5.5MVA Hitachi Transformer TRF-5501QBH 

• Installation, Termination and Commissioning of 1MVA Transformer TRF-5502QBH 

• Installation and Commissioning of Magellan 110 VDC Power Supply Cabinet  

• Supply, Installation and Commissioning of Remote I/O (SCADA) Panel. 

• Testing and of installed HV cables to 11kV Electrode Boiler and 2 Transformers from 11kV Switchboard.  

• Programming, Testing and Commissioning of Schneider Protection Relays.  

• As-built documentation.   

VALUE TO CLIENT 

• Reduces greenhouse gas emissions by enabling the transition from fossil fuel-based steam generation to electricity-powered steam production, supporting Fonterra’s decarbonisation strategy and emissions reduction targets.  

• Supports long-term sustainability objectives through the adoption of electrified process heat technology and increased utilisation of New Zealand’s renewable electricity network.  

• Improves energy security and resilience by replacing ageing gas-fired generation assets with modern electrical infrastructure designed to support future manufacturing demand and site expansion.  

• Future-proofs the Edgecumbe manufacturing site through investment in new 11 kV infrastructure, transformers, switchgear, protection systems, and capacity upgrades capable of supporting future production growth.  

• Provides reliable steam generation capacity required for dairy processing while reducing exposure to future fossil fuel supply constraints and carbon-related costs.  

• Maintains operational continuity through staged integration of new electrical assets into a live manufacturing environment, minimising disruption to production and site operations.  

• Enhances asset performance and reliability through modern protection systems, upgraded electrical distribution infrastructure, and improved monitoring and control capabilities.  

• Supports Fonterra’s broader North Island Energy Programme, creating a scalable platform for further electrification and decarbonisation initiatives across its manufacturing network. 

Sustainable Development Goals (SDGs) Supported: 

• SDG 7 – Affordable and Clean Energy: Enables the transition to renewable electricity-powered steam generation and improves energy sustainability. 

• SDG 13 – Climate Action: Reduces greenhouse gas emissions and supports Fonterra’s decarbonisation objectives. 

• SDG 9 – Industry, Innovation and Infrastructure: Delivers innovative industrial electrification technology and resilient electrical infrastructure to support sustainable manufacturing operations.