Electrical Installation for Biogas Plants: Building Safe and Smart AD Plants

Why Specialised Electrical Installation is Needed

Anaerobic digestion plants operate in hazardous environments where gases such as methane and hydrogen sulphide can form explosive atmospheres. In these conditions, electrical systems are not just about wiring – they are about safety, compliance and resilience.

Every piece of equipment must meet stringent ATEX and IECEx standards to ensure it can operate safely under these conditions. Without the right design and installation, operators risk dangerous system failures, HSE penalties and costly downtime.

Specialist electrical installation for AD facilities includes high-voltage distribution, tailored control panels, and automated process control for CHP, upgrading and digestate handling. Commissioning and testing by qualified engineers ensures every system is safe and operational before handover.

BioContractors’ Electrical Services

At BioContractors, we provide full-scope electrical solutions designed specifically for anaerobic digestion plants. Our team combines electrical engineering skill with biogas process knowledge to deliver systems that are both safe and performance-driven.

• Process automation and control systems
  Integration of sensors, PLCs, SCADA and human-machine interfaces to keep operators in control with real-time data.

• Safety systems and ATEX compliance
  Emergency stops, gas detection interlocks, intrinsically safe barriers and explosion-proof equipment designed to meet ATEX directives and UK regulations.

• Variable frequency drives (VFDs) and motor control
  Motor starters and inverter technology that reduce energy consumption, cut wear and extend asset life.

• Electrical risk assessments and arc flash analysis
  Compliance with BS 7671 wiring regulations and best practice hazard reduction for high-risk environments.

• Instrumentation installation and calibration
  Fitting and calibrating temperature, pressure, and gas sensors, including ATEX-rated biogas analysers for accurate process monitoring.

For more examples of our specialist work, see our mechanical fabrication on solid feeders case study and servicing of pressure release valves.

Benefits of Professional Installation

Investing in professional, ATEX-compliant electrical installation delivers tangible returns:

• Safety and compliance: Reduced risk of fire and explosion, meeting ATEX, IECEx and HSE standards.

• Operational efficiency: Automated control stabilises digestion, optimises CHP output and keeps downtime low.

• Future-proofing: Modular designs accommodate additional CHP engines, upgrading units or digestate processing equipment.

• Lower operating costs: Energy-efficient systems, predictive maintenance and remote diagnostics cut OPEX.

Electrical Systems in the Biogas Industry

As AD facilities scale up and become more complex, robust electrical infrastructure is now a cornerstone of success. Leading developers increasingly involve electrical specialists from the design phase, ensuring seamless integration with mechanical and process engineering.

Industry best practice includes:

• Hazardous area classification (Zone 1 and Zone 2) to define equipment specifications.

• Regular inspection and maintenance aligned with EA permits, ATEX directives and HSE guidance.

• Digital monitoring and automation for predictive maintenance, improved energy balance and grid compliance.

Non-invasive technologies such as Live Core Drilling complement these electrical solutions, enabling sampling and equipment installation without disrupting plant operations.

Frequently Asked Questions

What electrical standards apply to biogas plants in the UK?
All installations must comply with BS 7671 wiring regulations. Equipment in hazardous zones must also meet ATEX and IECEx standards.

What are hazardous area classifications?
Biogas plants are classified as Zone 1 or Zone 2 depending on the likelihood of explosive atmospheres. This classification dictates the type of ATEX-rated equipment required.

How often should electrical systems be inspected?
At least annually, with more frequent checks in high-risk areas. ATEX equipment requires scheduled servicing to maintain compliance.

Can existing plants be upgraded for ATEX compliance?
Yes. Retrofitting explosion-proof equipment, upgrading panels, and implementing gas detection systems can bring older facilities up to current standards.

How does automation benefit AD plants?
Automation provides real-time data, predictive maintenance insights, reduced downtime, and improved energy efficiency across CHP and upgrading systems.

How BioContractors Supports Your Electrical Installation

From initial design to long-term maintenance, BioContractors delivers electrical systems built for the unique demands of anaerobic digestion. Our ATEX-compliant solutions safeguard staff, protect assets and prepare your plant for growth.

Looking to strengthen your plant’s electrical infrastructure? Connect with our team today.