Upgrading Kensington substation

Project Name: Kensington substation upgrade
Location: Kensington, Whangārei
Investment: $22.4 million
Start Date: October 2024
Completion Date: September 2026
Project partners: Elsewedy Electric, MOVE Logistics, Hayes Metals, Steve Bowling Contracting, ESI Group, Woofe Contracting

Annual Report 2026

Investing in critical infrastructure locally

Northpower is focused on proactively investing in critical network infrastructure to ensure we can provide a reliable and resilient supply that can meet the increased demands of our connected consumers in Whangārei and Kaipara. 

The Kensington substation is the largest in our electricity distribution network, supplying power to more than 28,500 homes and businesses in the growing Whangārei district. 

Significant upgrades to this substation were completed to meet future increased demand, ensuring we can continue to provide a reliable power supply that serves the energy needs of our communities. 

$22.4m

total project investment

2

three-phase transformers to be installed

750

tonnes of soil moved for expansion

1265

person-hours invested

Upgrading assets to support growth

Upgrades include the construction of an additional building for a switch room, upgrading end-of-life switchyard equipment, the 110kV power transformers, and circuit breakers, and reconfiguring the switchyard to improve reliability. 

We invested $9.4 million in upgrading the substation in 2026, with the total investment for this project being $22.4 million.

This upgrade not only improves efficiency but also helps safeguard Northpower’s network against future challenges, ensuring homes and businesses continue to receive a stable and uninterrupted energy supply. 

Our biggest project in decades

Preparing the site

Significant civil work on the substation site was required to create room for the temporary pads and the additional switchroom building. With the help of local civil contractor, Steve Bowling Contracting, vegetation and embedded rock were removed from the site in late 2024. 

Next, the preparation for the foundations included constructing and backfilling retaining walls, removing 750 tonnes of contaminated soil to Redvale Landfill, and excavating and pouring concrete for the new transformer foundation pad. 

In a great example of sustainable thinking, the excavated rock was cleaned and repurposed to form the new southern embankment, finished with a Terralink rock mattress for a strong, stable, and visually tidy edge. 

 

Timelapse of Kensington substation site preparation

Moving things into place

Replacing the old transformers that had reached the end of their lifespan meant an opportunity to improve equipment. We sourced two purpose-built 110/33kV three phase 100MVA transformers from Elsewedy Electric in Indonesia. These purpose-built transformers are designed to operate more quietly in the residential area while doubling the substation’s capacity and providing improved security of supply. The size of the transformers meant they had to be moved from Northland Port in October 2024 using an oversized transport truck, and a series of constructed gantries. 

In June 2025, construction of the transformer pads was completed with the first of the 100MVA transformers moved into place. The switch room building construction phase was also completed before starting the internal fit out of the 33kV equipment. 

As part of the project, we secured the main lines that get the power from the grid exit point at Maungatapere to Kensington, which included flying in the equipment required by helicopter to the tower in the Western Hills. 

Bringing it all online

In October 2025, the second transformer was moved into its new position, and outdoor 110kV switching equipment and the indoor 33kV equipment were ready to go. The job of commissioning and livening this new equipment spanned five meticulously planned days. Our Transmission team assembled the remaining section of the new gantry, then carefully transferred the three heavy high voltage conductors from the old gantry to the new structure. Each conductor was realigned, lifted into position, secured to the new gantry and connected to the new transformer. With each line weighing close to 1,000kg, the work required careful handling, testing and verification before the new equipment could be livened. 

March 2026 marked a significant milestone for the transformer works, with the successful installation of the new T1 transformer onto its permanent pad in the switchyard. This achievement was the result of co-ordinated efforts between several specialised contractors. It was livened in June, before decommissioning and demolition of the old transformers began. 

From there, the project quickly moved into its next phase. The redundant T2 transformer and associated equipment were removed, clearing the way for the Civil team to get underway with drainage, foundations, and other essential works. The completion of the feeder cable cutover also opened up access to the new switch room, allowing several work fronts to progress in parallel. 

By August, the switchyard was taking shape. Redundant equipment and structures had been removed, the final bus tie equipment was installed, and testing was completed in preparation for the final commissioning outage. 

The final outage was successfully completed in September, commissioning the bus tie and bringing the new Kensington substation fully online. 

Working together and minimising the impact

Construction of the switch room, and installation of transformers and switchgear was completed in stages, with equipment being commssioned and lived at the completion of each of the construction stage to minimise any power outages to customers.  

The first transformer was livened and the realignment of the last span of the high voltage conductors from Maungatapere was all completed on de-energised equipment, without any power outages to our customers. 

The size and scale of this project has drawn on the specialist skills from a number of Northpower teams, including our Network, Transmission, Energy Services and Electrical Services teams, supported by several external contractors. 

Civil works were consented by Whangārei District Council and were undertaken during regular working hours. This included the digging and levelling of the site, trenching and hydro extraction, and rock breaking, which were all done with noise-mitigation measures in place.

Increasing the resiliency of our network

This extensive project is the biggest singular upgrade to our network in decades, shows our commitment to increasing the resiliency of our network, and the reliability of supply, for our local communities.

Full scope of works:

  • Replacement and reconfiguration of 110kV outdoor switchyard, including new circuit breakers and associated equipment.
  • Replacement of six 110/33kV single phase transformers (designated as T1 and T2) with two new 110/33kV three phase 100MVA transformers.
  • Construction of a new 33kV switchroom building to house a replacement 33kV switchboard.
  • Upgrading of all 110kV and 33kV protection at the substation.

More resilient network case studies and articles...

Maungatapere to Kensington 110KV tower refurbishment

To enhance reliability, Northpower carried out a $4 million refurbishment on the main supply route that electrifies half of Whangārei.

Upgrading key Northland substations

Across Dargaville and Maungatapere, Northpower is upgrading substation infrastructure and installing new connections to enable renewable electrification and increased capacity.

Partnering with the Mangawhai community

Partnering with landowners and hapu, Northpower is delivering 33kV infrastructure to support growth in Mangawhai while enabling timely, community-led project outcomes.