Brabo III: facilitating the import and export of electricity
Equans building and upgrading High-Voltage infrastructure for Elia
The need for a transition towards sustainable, reliable, and affordable electricity is undeniable. Elia stands as a key driver in enabling this transformation, exemplified by projects such as the extensive Brabo project in and around Antwerp. The third phase of this project spans from the Liefkenshoek in the Port of Antwerp to the Mercator high-voltage substation in Kruibeke. Equans, a specialist in electricity networks and a longstanding partner of Elia, plays a vital role in the crucial task of renewing the high-voltage lines.
A reliable partner for tomorrow’s power supply
With the Brabo III project, Elia aims to achieve three goals. Firstly, the Belgian transmission network operator is reinforcing the existing 380 kV network in Belgium, as this voltage level forms the backbone of our Belgian electricity grid. Thanks to the upgraded and enhanced connection, Elia will be able to transport up to 20% more electricity through the 380 kV network.
Furthermore, the operator will be able to better distribute renewable electricity flows, which are increasingly being integrated into the grid. Lastly, Belgium and the Netherlands will have improved capabilities for importing and exporting electricity, crucial for a well-functioning European electricity market.
How does Brabo III work exactly?
First, Elia laid two new underground cable links (150 kV) between the Kallo and Fort Sint-Filips high-voltage substations and between the Kallo and Beveren-Waas high-voltage substations. This is necessary to maintain sufficient capacity during the works on the 150 kV high-voltage line between the Liefkenshoek and the Mercator high-voltage substation in Kruibeke.
Elia is dismantling the existing high-voltage line to reconstruct it as a new, reinforced 380 kV high-voltage line. This process involves mainly constructing new masts on the existing mast locations. The high-voltage line will be a crucial link in the Belgian electricity grid. To accomplish the extensive Brabo III project, Elia relies on the expertise of Equans.
Project in full swing
Since the end of 2022, the preparatory line works for the Brabo III project have been in full swing and will continue until mid-2025. "The Mercator high-voltage substation is undergoing significant expansion, which required us to reconfigure the existing 380 kV lines north of the substation over the past months," says Didier Janssens-Petit, Project Manager - High-Voltage Lines at Equans. "We replaced the existing conductors and followed a new route. We also erected four new masts, each 55 meters high." These are already impressive structures, but throughout the entire Brabo III project, Equans will build a total of 58 new masts, including some over 130 meters high.
Meanwhile, the teams from Equans' 'substations' department, specialized in onshore substations, are carrying out work at the Mercator high-voltage station itself. "We are expanding Mercator with five new 380 kV fields and a 380 kV cross-connection across three 380 kV rail systems. At the same time, we are making significant adjustments to achieve a better redistribution of power load on both sides of the station," explains Patrick De Bruyn, Section Manager - Substations. "We deliver and install the necessary lattice structures on which we place the newly supplied 380 kV high-voltage equipment. Additionally, we install a new third 380 kV rail system, spanning a total length of approximately 540 meters, divided into 27 fields of 380 kV. In various fields, we need to replace several high-voltage devices to accommodate a higher short-circuit capacity (63 kA). For all new high-voltage devices, we provide new high-voltage connections and renew the low-voltage cables. Furthermore, we equip two completely new buildings (relay rooms) with various security panels and a new distribution of power circuits (110V DC and 400/230V AC). One building has already been fully tested and commissioned, while the other will follow soon."
The big challenge
The major challenge lies in the expansion of the five fields at the Mercator high-voltage station, which had to be completed by the end of April 2023, as Equans' colleagues were ready with the new high-voltage lines. This illustrates one of Equans' significant strengths: the ability to plan and execute work correctly within tight deadlines. "You can't just start working on a high-voltage line," explains Didier Janssens-Petit. "Elia must first take the line out of service, a process known as 'cutting.' The operator plans this well in advance. So when we work on the high-voltage line, we have to do it within the scheduled, and sometimes limited, timeframe."
Equans succeeds in this regard because the company has already installed thousands of kilometers of high-voltage lines with various types of conductors of every diameter. Experience is not lacking. "First, we remove the old conductors by mechanically winding them from one mast to another using state-of-the-art machines. We protect everything located under and around the masts to prevent any possible hindrance or damage. New conductors are then pulled when the new masts are erected. So far, the ongoing project has been progressing well in this aspect. However, we will soon be building directly in the Port of Antwerp, above industries, locks, railway tracks... That will pose a significant challenge."
Equans is also responsible for the demolition of the old 150 kV masts, which is necessary for the construction of the new 380 kV masts. The installation of new foundations is usually outsourced to other specialized contractors by Elia. "At Equans, we then assemble and erect the masts. Often, we first assemble manageable mast modules on the ground, which are then further assembled using telescopic cranes. How quickly do we build such a mast? From a little over a week to three to four weeks for a heavy 380 kV mast, depending on the environment and weather conditions. In this project, we assembled and erected one mast in just under ten days."
What’s next?
The Mercator high-voltage substation was rebuilt, the existing 380 kV high-voltage lines were relocated, and the start was given for the arrival of the new 380 kV high-voltage line. But that’s just the beginning of the Brabo III project. The works will continue at least until the end of 2025. Meanwhile, Equans is also involved in reinforcing Belgium’s 380 kV grid at other locations on behalf of Elia for sustainable, affordable electricity supply today and tomorrow.