ICPs (Independent Connection Providers), EPCs (Engineering, Procurement & Construction firms), DNOs (Distribution Network Operators), and IDNOs (Independent Distribution Network Operators) are today facing surges in control system and panel demand that strain their usual suppliers.
Long lead times, limited capacity from smaller panel builders, and fragmented design/build processes can put critical project timelines at risk. PP Control & Automation (PP C&A) has joined forces with specialist transmission Protection & Control engineering firm, TES, to eliminate these bottlenecks with a single-source, end-to-end design and build solution.
When multiple projects or grid connection deadlines hit at once, smaller control panel builders struggle to keep up, leading to delays or rushed work.
Niche panel shops lack the capacity and advanced facilities to handle high-volume or complex builds, resulting in long lead times and quality issues.
Hiring separate design consultants and panel manufacturers can introduce miscommunication, integration problems, slowing down projects.
Ensuring every component meets strict industry standards (electrical, structural, safety) is harder when responsibilities are split among multiple vendors.
Specialist transmission engineering expertise brings design, build and integration closer together, helping to remove one of the biggest sources of risk in complex grid and energy infrastructure projects.
Through our collaboration with Transmission Engineering Services (TES), projects can access extensive protection and control engineering capability across both greenfield and brownfield applications. TES transforms high-level concepts into detailed, buildable engineering solutions, supported by dedicated design, test, CAD, document control and project management resources.
With NERS Design Accreditation up to 132kV and proven experience delivering protection and control engineering across 275kV and 400kV transmission infrastructure, TES brings the specialist knowledge required to integrate new systems safely into both new and existing substations.
Their experience spans major transmission schemes, GIS and AIS substations, feeder and SGT protection, busbar systems, synchronous condensers and complex brownfield protection replacement programmes.
a. Site-specific protection and control scheme design
b. Single line, key line, schematic and logic diagrams
c. General arrangements and wiring diagrams
d. Cable block diagrams, cable schedules and fibre optic diagrams
TES specialises in taking high-level concepts through to detailed working protection and control designs, whether for completely new installations or integration into existing operational systems.
Designs consider staged works, system constraints and outage requirements from the outset, helping ensure that what is engineered can be efficiently manufactured, installed and commissioned.
a. New-to-existing system interface engineering
b. Electrical interlocking and control system integration
c. Control system I/O and database information
d. Brownfield modification and staged implementation
TES has significant experience engineering the interfaces between new protection equipment, existing assets and third-party systems, particularly where infrastructure needs to remain operational throughout a phased upgrade.
This includes complex brownfield schemes where new protection, control and monitoring systems must be introduced whilst retaining elements of the existing installation.
a. Protection relay settings and configuration
b. AC and DC loading calculations
c. Cable sizing and voltage-drop calculations
d. Pre-FAT and FAT support
Dedicated protection engineers provide settings calculations, relay configuration and detailed technical documentation alongside the structured testing required to verify system performance.
TES can support the engineering process through pre-FAT and FAT, creating a stronger connection between design intent and the finished protection and control panels manufactured by PP C&A.
a. CDAE and National Grid design governance support
b. Design Intent Documents and Functional Design Specifications
c. CAD, drawing management and construction boxes
d. As-built drawings and project documentation
Robust engineering documentation and governance sit behind every successful transmission project.
TES provides engineering governance, CAD, document control and drawing management alongside project management, CDM, Temporary Works and Principal Designer support.
The result is greater control from initial engineering through manufacture, installation and final project handover.
Detailed protection and control engineering for new-build and existing transmission infrastructure.
From schematics, wiring and general arrangements through to cable schedules and cubicle design, TES develops practical engineering packages ready to move efficiently into manufacture and implementation.
Specialist engineering for the integration of new systems with existing operational infrastructure.
TES considers legacy equipment, interlocking, control interfaces, staged construction and outage constraints to minimise disruption and reduce integration risk.
Protection settings, relay configuration, electrical calculations and structured testing support provide technical assurance throughout the engineering process.
Pre-FAT and FAT capability also creates a direct link between engineering design and the panels manufactured by PP C&A.
From site surveys, Design Intent Documents and CAD through to design governance, project management, Principal Designer support and as-built documentation, TES provides the engineering infrastructure required to take complex transmission projects from concept through to handover.
Full-service capability in the manufacture of protection and control panels, and electrical assemblies with world-class quality. Core disciplines include control system builds, pneumatics, hydraulics and fluid systems, mechanical design & assembly, vacuum chambers & gas management systems, and cable harnessing.
The depth of engineering and production capabilities available through strategic partnership with PP C&A make for one of the most flexible and scalable solutions in the UK.
This flexibility is particularly relevant for ICPs, EPCs, DNOs, and IDNOs, where they are undertaking projects that require several disciplines for system and machine builds.
These disciplines can be combined to provide critical solutions for work on electrical substations and renewable energy installations, energy storage systems or industrial control & automaton systems, and exciting smart grid technology and grid modernisation projects.
Design and build of electrical control & automation systems, with over five decades of value add engineering solutions for the manufacture of control panels. Competent in delivering a host of protection and control panels for the energy sector and grid upgrade projects – detailed below.
Electronics assembly, supporting floor standing suites to small, complex box builds, and the often stringent demands for electro-static discharge with dedicated ESD facilities.
Support in the design and assembly of pneumatic, hydraulic, and fluid systems by connecting components such as cylinders, actuators, and valves using tubing and fittings, as well as assembling any other mechanical or electrical components necessary.
Supporting everything from simple fabrication assembly to complex mechanical integration. Often includes the integration of subsystems such as power transmission, actuation, and sensing.
Valuable experience and competence in the sourcing and assembling of vacuum chambers and associated gas management systems. Assembly includes installation of vacuum pumps, valves, gas handling systems, and other components that make up the complete system.
£millions invested in automated production and test equipment for cable harnesses, utilising a 100% test regime. Over £2m has been invested in state-of-the-art fully automated cable preparation. Single and multicore cable processing, and design and manufacture of complete drag chain solutions.
Protection panel solutions for reliable grid performance.
Experience tells us that ICPs, EPCs, DNOs, and IDNOs require various types of protection and control panels for grid connections, substations, and power distribution projects. Those needs can be fulfilled through an approach that leans on decades of industry know-how.
| Role | Applications |
| Provide electrical protection for high-voltage (HV) and extra-high-voltage (EHV) systems, ensuring fault detection and isolation. | ○ Overcurrent and earth fault protection ○ Distance protection ○ Differential protection (busbar, transformer, generator) ○ Feeder protection ○ Line protection (e.g., transmission and distribution networks) ○ Generator and motor protection panels |
| Standards |
| National Grid, DNO, and IEC/IEEE protection relay standards. |
| Role | Applications |
| Facilitate real-time monitoring, automation, and control of substations and distribution networks. | ○ SCADA interface for remote operations ○ Data acquisition from transformers, circuit breakers, and switchgear ○ Communication with control centres via protocols (IEC 61850, DNP3, Modbus) |
| Considerations |
| Cybersecurity compliance for critical national infrastructure. |
| Role | Applications |
| Provide auxiliary power for substation control, protection, and communication equipment. | ○ Powering substation lights, HVAC, and auxiliary circuits ○ Providing backup power for protection relays, trip circuits & emergency ops |
| Standards |
| Must comply with DNO specifications for redundancy, reliability, and battery backup. |
| Role | Applications |
| Control and automate switchgear operation, ensuring safe and efficient power distribution. | ○ Control and monitoring of 11kV, 33kV, 132kV switchgear ○ Automatic reclosing and interlocking functions ○ Synchronisation of multiple power sources (grid-tie applications) |
| Role | Applications |
| Protect transformers from faults and ensure voltage regulation via on-load tap changers (OLTC). | ○ Transformer differential protection ○ Tap-changer automation for voltage regulation ○ Cooling system control (fan, oil pump, temperature monitoring) |
| Role | Applications |
| Measure and monitor power quality parameters for compliance with grid codes and operational efficiency. | ○ Voltage, current, power factor, harmonics monitoring ○ Revenue metering for substations and ICP installations ○ Load profiling for industrial and renewable energy customers |
| Role | Applications |
| Control and integrate solar PV, wind, battery storage, and EV charging infrastructure with the grid. | ○ Grid synchronisation for distributed generation (DG) ○ Frequency and voltage control for renewables ○ Hybrid energy system management (solar + storage + grid) |
| Role | Applications |
| Optimise power distribution and load balancing in industrial and grid applications. | ○ Load shedding and demand response control ○ Peak demand management for energy cost reduction ○ Dynamic load sharing for multi-source grids |
| Role | Applications |
| Ensure safe substation operation by preventing unsafe switching sequences. | ○ GIS (Gas-Insulated Switchgear) and AIS (Air-Insulated Switchgear) interlocking ○ Busbar transfer schemes ○ Redundant safety logic for high-risk switching |
It is common knowledge that this range of panels is in high demand, particularly as grid modernisation, renewables integration, and network expansion continue to drive investment in new substations and control systems.
Now there is a partner you can trust to meet that demand.
High-voltage protection engineered for grid reliability.
Seasoned engineers design the electrical schematics, civil layouts, and structural plans for your substations or power systems, whilst PP C&A simultaneously builds the required control panels and assemblies. This parallel workflow compresses delivery schedules, with combined teams providing faster, more productive results without sacrificing quality.
As the largest control panel builder in the UK, PP C&A brings significant production capacity and automation investment. It can adapt to peaks in demand with agility, ensuring on-time delivery even when your project load spikes. Unlike smaller firms, an extensive and award-winning 5,500 sq m² facility with 200 skilled workers, trained in-house; prevent bottlenecks, maximise output, and react to peaks and troughs in demand.
Joint teams coordinate at every step, so design intent aligns perfectly with build execution. A “buildable” design philosophy means plans are optimised for real-world construction, and rigorous assembly standards (Trusted by many of the world’s most successful machine builders) ensure reliable and compliant panels. The result is a turnkey solution with no gaps in responsibility or quality oversight.
| Phase | Key Activities | Capabilities |
| Feasibility & Planning | Grid connection feasibility study, regulatory approvals, DNO negotiations | Compliance advisory, electrical network planning, load flow studies |
| Design & Engineering | CAD design, substation layout, protection schemes | Electrical, civil, and structural design, G99/G100 compliance, digital twin modeling |
| Procurement & Pre-Fabrication | Sourcing switchgear, transformers, control panels, modular substations | Supply chain management, cost optimisation, pre-built electrical enclosures |
| Site Preparation & Civil Works | Excavation, foundations, cabling routes, wayleave approvals | Civil engineering, groundworks, trenching, installation logistics |
| Electrical Installation | Low to extra-high voltage system setup, cable jointing | Installation of switchgear, transformers, metering equipment |
| Testing & Commissioning | Protection relay testing, SCADA integration, final DNO approvals | Pre-commissioning, grid compliance testing, energisation support |
Our experience has taught us some very clear things: efficiency, reliability, and scalability are non-negotiable. Our collaborative approach brings together the best in engineering, manufacturing, and compliance expertise to redefine how ICPs, ECPs, DNOs, and IDNOs achieve their project goals.
By integrating design and build phases, we eliminate unnecessary delays. No more waiting for designs to be finalised before production begins – our teams work in tandem, shrinking project schedules and accelerating energisation. When designers, engineers, and manufacturers work as one, errors are minimised, and quality is maximised. Every panel is built to the highest standards, and every design is rigorously vetted for compliance and real-world practicality.
Large-scale projects and peak demand periods are no longer a bottleneck. Our expanded capacity and integrated supply chain ensure that you can take on more without compromise, maintaining consistency across every project. One team. One vision. One accountable partner. With continuous communication between design and production teams, issues are resolved faster, and risks are mitigated before they escalate – giving you peace of mind and fewer coordination headaches.
Our expertise spans everything from network designs up to 132 kV to OEM-grade panel builds that meet the strictest quality standards. Every project is fully documented, tested, and delivered in accordance with DNO requirements and all relevant electrical codes.
This is more than just an outsourced service – it’s a smarter way to build the future of grid connectivity.
TONY HAGUE
Director, PP Control & Automation
One of the UK’s leading strategic manufacturing specialists is tapping into the UK’s unprecedented investment in upgrading the electricity grid.
As Britain accelerates investment in grid infrastructure, protection and control capacity could become a critical delivery constraint.
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