Brabo III project enhances distribution of green electricity
The need for a transition to sustainable, reliable and affordable electricity is undeniable. Elia is at the forefront of enabling this shift, particularly through the extensive Brabo project in and around Antwerp. The third phase of the project extends from Liefkenshoek in the Port of Antwerp to the Mercator high-voltage substation in Kruibeke. Equans, as Elia’s long-term partner, is responsible for the critical renewal of the high-voltage lines.
Reliable partner for tomorrow’s power supply
Elia is pursuing three goals with the Brabo III project. Firstly, it strengthens the existing 380 kV network in Belgium, which is the backbone of our national electricity grid. With the upgraded connection, Elia will be able to transport up to 20% more electricity through the 380 kV network.
The project will also enable better distribution of the increasing renewable electricity flows onto the grid. And finally, it will facilitate easier import and export of electricity between Belgium and the Netherlands, which is vital for a well-functioning European electricity market.
What exactly is Brabo III?
Elia first installed two new underground cable connections (150 kV) between the high-voltage substations at Kallo and Fort Sint-Filips, and between Kallo and Beveren-Waas. This ensures sufficient capacity is maintained during the upgrade of the 150 kV high-voltage line from Liefkenshoek to the Mercator substation in Kruibeke.
Elia will dismantle the existing high-voltage line and rebuild it as a new, reinforced 380 kV line, mostly using new masts at the existing sites. This line will be a crucial link in the Belgian electricity network. Elia is relying on Equans’ expertise to realise the extensive Brabo III project.
Project in full swing
Preparatory line works for the Brabo III project have been in full swing since late 2022, with completion expected by the end of 2025. “The Mercator substation is undergoing significant expansion, necessitating the reconfiguration of the existing 380 kV lines to the north of the substation,” explains Didier Janssens-Petit, High-Voltage Line Project Manager at Equans. “The existing conductors have been replaced and rerouted. We’ve also erected four new masts, each standing 55 metres tall.” These are already impressive structures, but throughout the Brabo III project, Equans will construct a total of 58 new masts, including some that exceed 130 metres in height.
Teams from the ‘substations’ department, specialising in onshore substations, are also actively involved in the project. “Our task includes expanding Mercator with five new 380 kV fields and a 380 kV cross-link over three 380 kV rail systems, as well as a significant adjustment to better redistribute the power load across both sides of the substation,” says Patrick De Bruyn, Section Manager at Equans. “We’re also responsible for installing the necessary frameworks for the new 380 kV high-voltage equipment and a new third 380 kV rail system, spanning approximately 540 metres across 27 fields. “We’ve equipped two new buildings (relay rooms) with various protection panels and a new distribution of power circuits (110V DC and 400/230V AC).”
The big challenge
Equans is on track to complete the expansion of the five fields at the Mercator high-voltage substation by the end of April 2023, just in time for the new high-voltage lines to go live. This highlights one of Equans’ key strengths: meticulous planning and execution within tight deadlines. “You can't just start working on a high-voltage line,” explains Didier Janssens-Petit. “Elia first needs to decommission the line, a process known as ‘cutting’. This is scheduled well in advance, So when we work on the high-voltage line, we have to do it within the predetermined and sometimes limited timeframe.”
Equans’ success in this area stems from its extensive experience, having laid thousands of kilometres of high-voltage lines with various types of conductors of every diameter. “We start by removing the old conductors, mechanically rolling them up from one mast to the next using the latest machinery. We take great care to protect everything under and around the masts from potential disruption or damage. New conductors are then installed later once the new masts have been erected.”
The dismantling of the old 150 kV masts – a necessary step for the construction of the new 380 kV masts – is also part of Equans’ remit. “We started dismantling the existing 150 kV line in August 2023, and this operation will continue until the end of February 2024. All conductors and pylons, except one, will have been removed by then for lot 1 – between Liefkenshoek and the Kallo substation. We’re waiting for the cutting of a nearby 380 kV line to safely dismantle that remaining mast. During the dismantling, we’ve had to navigate around challenging obstacles, such as the constantly active Kallo lock and a golf club. We’ve also implemented numerous protective measures for the disassembly of masts located in a minefield of utility lines. A highlight was removing two massive masts, each 117 metres tall and weighing 125 tonnes,” shares Didier Janssens-Petit.
“We faced numerous difficulties on the stretch from Kallo to Mercator, including the Rietveld Kallo nature reserve, crossing over the E17 and E34 motorways – which were completely closed during night works – and crossing over five bundled and electrified railway lines. We used a special netting structure for these railways, connected to the mast of a telescopic crane in Kallo and a scaffolding structure for protection in Beveren.”
Elia typically outsources the laying of new foundations to other specialised contractors. “At Equans, we then assemble and erect the masts. We often start by constructing manageable mast modules on the ground, which are then stacked using telescopic cranes. The construction time for a mast can range from just under a week to three to four weeks for a heavy 380 kV mast, depending on the environment and weather conditions. For this project, we assembled and erected a mast in just under ten days.” This phase will continue until the end of April 2025. Equans will start installing the new conductors in October 2024.
What’s next?
The Mercator high-voltage substation has been refurbished, the existing 380 kV high-voltage lines have been relocated, and progress on the new 380 kV high-voltage line is well underway. The works are set to continue until the end of 2025. And meanwhile, Equans is also working elsewhere to reinforce Belgium’s 380 kV grid on behalf of Elia to ensure a sustainable, affordable electricity supply today and tomorrow.