LEV System Upgrade

Client Requirement

A facility constructed in 1982, faced increasing compliance challenges with its ageing Local Exhaust Ventilation (LEV) system. As the primary construction facility for submarine builds, the existing LEV infrastructure no longer met modern operational, safety, and environmental standards. Our client required a full upgrade of the LEV and HVAC systems to ensure compliance with current regulations, improve energy efficiency, and future-proof the facility for ongoing and upcoming projects. The solution needed to align with the clients Net-Zero Carbon by 2030 goals while delivering a robust, sustainable, and fit-for-purpose ventilation system.

Our Solution

BGEN, developed a robust RIBA Stage 1 design, provided a comprehensive solution that encompassed LEV, HVAC, electrical and control infrastructure, process control systems, and structural assessments. Partnering with MECHON Ltd as the preferred LEV designer, BGEN delivered a concept design addressing the facility’s operational and environmental requirements.

The electrical infrastructure was assessed in detail, with the existing 200-amp busbar trunking identified for reuse. A thorough load assessment confirmed that sufficient capacity existed to support the new systems, avoiding the need for major upgrades to the primary distribution network. However, ageing Motor Control Centres (MCCs), installed in the 1980s, were replaced with modern, compact MCCs controlling advanced Variable Speed Drives (VSDs). To maximise efficiency, VSDs will be strategically mounted near fans to reduce footprint and installation costs.

Control system upgrades included integrating new LEV operations into the existing Building Management System (BMS). BGEN propose a solution that allows seamless control and monitoring via intuitive interfaces located in key operational areas. This integration eliminated the need for standalone control PLC system, reducing complexity and maintenance costs.

Initial structural integrity assessments, identified that gantries and support structures could accommodate the additional equipment load, 3D laser scanning of the existing facility, will facilitate generation of Revit models to be generated enabling precise design coordination and ensuring clash-free installations.

BGEN also implemented a Whole Life Carbon Assessment (WLCA) in collaboration with Tunley Environmental providing value-added engineering. A WLCA was developed to quantify and reduce greenhouse gas (GHG) emissions at each stage of the project, ensuring alignment with the client’s environmental objectives.

Client Benefits

• The upgraded LEV system delivers a significant improvement in operational performance, safety, and energy efficiency. By reusing existing infrastructure where possible, BGEN provided a cost-effective solution while minimising disruptions to ongoing operations. Modern MCCs and VSDs have enhanced energy management, reducing operational costs and extending equipment life.
• The integration of LEV controls into the existing BMS ensures streamlined operations with real-time monitoring and control capabilities. Enhanced user interfaces and advanced instrumentation improve system visibility, reducing downtime and maintenance requirements.
• BGEN’s sustainability-focused approach has supported our client’s Net-Zero Carbon by 2030 commitment. The WLCA and energy-efficient solutions deliver measurable reductions in carbon emissions, ensuring compliance with regulatory standards and sustainability goals.
• Through detailed stakeholder engagement, collaborative workshops, and advanced digital modelling, BGEN provided a future-proof, scalable solution that positions the facility to meet the demands of future manufacturing programmes. The RIBA Stage 1 design serves as a robust foundation for subsequent development phases, ensuring operational excellence for years to come.