BGEN Leads E&I Installation for Ingevity's Polymer Power Centre Upgrade
Client Requirement
Ingevity, a global leader in speciality chemicals and materials, required a substantial upgrade to the company’s Polymer Power Centre at its Warrington, UK facility, where the company manufactures industry leading polycaprolactone materials that help produce safer, more sustainable, and higher performing products for a wide variety of end use markets.
The objective of this upgrade was to replace the existing power unit with a larger, modernised version that would enhance operational efficiency and ensure reliable power distribution to meet anticipated future demands. This project was carefully planned to coincide with a scheduled site shutdown, requiring a phased approach to minimise downtime and disruption.
Our Solution
BGEN was appointed to manage the critical upgrade of Ingevity’s Electrical & Instrumentation (E&I) installation. To minimise disruption, we developed a phased, collaborative approach to meet Ingevity’s requirements effectively and maintain project efficiency.
The project began with a pre-shutdown phase focused on essential preparations for a smooth transition to the main installation. During this phase, BGEN installed new cable containment systems, fibre optic cabling, and temporary power solutions, ensuring infrastructure readiness for the primary work, reducing the risk of delays, and strengthening our preparation for the next phase.
During the scheduled site shutdown, BGEN handled the decommissioning of the old Power Centre and installation of the upgraded components, including new power cabling and panels. We worked closely with Ingevity’s team and other on-site contractors, coordinating activities to adhere to the tight project schedule and ensure smooth installation and commissioning of the new system.
The project presented significant challenges, including a short timeline and limited workspace shared with other subcontractors. These constraints required close coordination to ensure all teams could work efficiently within a confined area. To address this, BGEN held daily meetings with Ingevity and all subcontractors, keeping everyone informed of activities, optimising schedules, and reducing potential overlaps.
This collaborative approach was essential for maintaining project momentum despite space limitations and tight deadlines.
After completing the primary installation, BGEN conducted a meticulous post-installation phase to reconnect existing systems to the new Power Centre. Our team carried out extensive testing and commissioning to ensure seamless functionality and integration with Ingevity’s larger infrastructure. This final phase reinforced the system’s reliability, providing Ingevity with confidence in their upgraded power capabilities and securing robust performance for future demands.
Client Benefits
Minimum Disruption: Our phased strategy minimised downtime, allowing Ingevity to maintain steady productivity while we conducted the upgrade, even amid complex logistical challenges.
Collaboration and Transparency: The focus on daily collaboration meetings and transparent communication with all contractors enabled the project to stay on track, overcoming the challenges posed by the short timescale and limited workspace.
Safety First: Adherence to rigorous safety standards further ensured an incident-free environment, protecting both personnel and assets. By leveraging our extensive E&I expertise, Ingevity received a timely, high-quality outcome that met their evolving operational needs and aligned with their commitment to safety and efficiency.
