BGEN is collaborating with Novelis on an ambitious hydrogen trial at their GPP Furnace No.3 site in Latchford, Warrington. This pioneering initiative forms part of the UK Government’s £55 million Industrial Fuel Switching (IFS) programme under the £1 billion Net Zero Innovation Portfolio (NZIP) and is also connected to the broader HyNet project in the region. The project’s goal? To replace the furnace’s natural gas supply with hydrogen, underscoring Novelis’s commitment to sustainable energy solutions.
The trial focuses on assessing the furnace’s performance with hydrogen as a fuel source, aiming to reduce carbon emissions and improve energy efficiency. Once the trial concludes, all equipment will be removed, and the site returned to its original state, demonstrating BGEN’s capability to execute temporary installations with minimal impact on ongoing operations.
With Otto Simon serving as the principal designer and contractor, BGEN has been awarded the Mechanical, Electrical, and Instrumentation (ME&I) responsibilities. BGEN is tasked with the installation of complex systems and instrumentation to support the hydrogen trial’s success.
BGEN’s expertise spans full project delivery, and for Novelis, this means managing everything from sourcing and installing piping components to fabricating and assembling custom pipe spools and the Stage 2 Pressure Let-Down Skid. Each element undergoes meticulous inspection and testing to uphold high-quality standards.
The team is overseeing the full installation, including detailed planning, site management, instrument tubing installation, and supervision to ensure compliance with all Construction Design and Management (CDM) regulations. Onsite safety is paramount, with secure facilities, including Heras fencing and secure storage, in place to maintain smooth and safe operations.
In support of Novelis, BGEN is providing an array of ME&I services:
- Mechanical Services: Fabrication and assembly of piping, pressure let-down skids, and support structures for strong mechanical integration.
- Electrical Control and Instrumentation: Design verification, supply, installation, and commissioning of electrical control and instrumentation systems.
- System Integration: Installation of hydrogen detection systems, emergency stops, and grounding systems to ensure safe, efficient operation.
- Testing and Commissioning: Comprehensive testing to verify compliance with BS 7671 and BS EN 60079 standards, including loop testing and point-to-point verification.
Through detailed planning and precise execution, BGEN is delivering a streamlined installation process that aligns with all regulatory and safety requirements. The high-quality fabrication and reliable integration of components are critical to the success of the trial, reflecting Novelis’s sustainability ambitions.
By facilitating a smooth, minimally disruptive operation, BGEN is helping Novelis advance its goal of an efficient, low-emission hydrogen supply system. With a focus on safety and regulatory adherence, this partnership positions Novelis as a leader in sustainable energy innovation, setting a benchmark for the industrial fuel-switching sector.
Source: b-gen.co.uk "Leading the Charge in Industrial Fuel Switching: BGEN's Ongoing Hydrogen Trial at Novelis" BGEN News
