Introduction
Client: Amazon Basildon (DSS2)
Location: Unit 1, Gateway Park, Christopher Martin Road, Basildon, Essex
Date of Work: March 2024
Background
As part of a pre-planned maintenance (PPM) visit to the Amazon Basildon facility, Express Solutions Group carried out diagnostic testing on the site’s surface water pump station. The purpose of the visit was to assess the performance of the existing drainage control system and ensure reliable operation of the pumps supporting critical surface water management.
During the inspection, the engineering team identified electrical communication issues between the control panel and the pump station. The control panel was located approximately 55 meters away from the pump chamber, creating challenges in maintaining a consistent signal over distance.
Project Background
The existing setup featured:
- Two pumps operating in a duty and assist configuration.
- Four float switches (three controlling pump operations and one managing high-level alarms).
- A 2.5 SY high-level cable running between the control panel and pump chamber.
Testing revealed:
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- Both pumps passed insulation resistance tests at >2200 MΩ and operated within normal overload parameters.
- However, intermittent fuse faults were detected in the secondary control circuit (initially 2A, later replaced with a 4A fuse), with the problem persisting.
- The SY signal cable was identified as unsuitable for a wet environment, leading to potential degradation and impedance increase over time.
- The 24V control signal was deteriorating across the long cable distance, causing unreliable communication between the float switches and the control panel.
Solution Provided
Express Solutions Group recommended:
- Replacement of the existing control panel with a GSM Pulsar Militronic-type control panel, ensuring uninterrupted signal transmission between the chamber and the control system.
- Installation of a new rubberised flexible cable to replace the existing SY cable, designed for performance in wet environments.
- Reutilisation of existing ducting (subject to inspection and integrity confirmation)
Scope of Works
- Cordoning off the work area to ensure site safety.
- Performing safe electrical isolation of all relevant components.
- Removal of the existing control panel.
- Installation of the new GSM Pulsar Militronic-style control panel.
- Removal of existing cabling and pulling new rubberised flex cable through existing ducting.
- Electrical connection of all components and functionality testing.
- Recommissioning the system back into service.
Health and Safety Compliance
All works were undertaken in accordance with the Health and Safety at Work Act 1974, following Express Solutions Group’s internal HSE standards:
- Comprehensive method statements and risk assessments for each phase.
- Full PPE compliance: hard hats, high-visibility clothing, safety boots, gloves, and eye protection.
- Continuous adherence to safe isolation and control of electrical hazards.
Outcome
The project successfully:
- Eliminated intermittent electrical faults.
- Improved signal reliability between the pump chamber and control panel.
- Enhanced operational resilience of the site’s drainage pump system.
- Ensured compliance with environmental and safety standards.
The upgrade provided Amazon Basildon with a robust, future-proof control infrastructure, reducing maintenance risks and potential downtime during heavy rainfall events.
Key Takeaways
- Long cable runs at low voltage (24V) can lead to significant signal loss over distance.
- Appropriate cable selection for environmental conditions is critical for reliability.
- Upgrading to GSM-enabled control systems enhances monitoring and reduces reactive maintenance needs.
Client Feedback
Amazon Basildon’s facilities management team expressed satisfaction with the clear communication, technical expertise, and efficiency demonstrated throughout the project. The solution provided improved system stability and reduced future risk of electrical failures.
