INEOS Inovyn
INEOS Inovyn is the chlorovinyls supplier of choice for manufacturers around the world and is at the heart of Europe’s chemical industry. It delivers products essential for modern life which are found in almost every aspect of society, keeping people housed, healthy and connected.
Bethell Construction was appointed as the principal contractor for works taking place at INEOS Inovyn’s Northwich site, after engaging under competitive procurement to deliver additional wellheads and a series of new haul roads to increase capacity and accessibility across the site.
The works have been completed over a period of 16 months and will provide increased capacity for solution mining and processing along with the distribution of brine, a key raw material for producing chlorine, caustic soda, chlorinated derivatives, and food-grade salt.
- 4 new wellhead drilling pads
- 400m3 of structural concrete
- In excess of 10,000 tonnes of aggregate
- 2830m of process pipework
- A new concrete process chamber
- 5km of HV & LV cabling
The project involved Bethell installing four new wellhead drilling pads consisting of over 400m3 of structural concrete and in excess of 10,000 tonnes of aggregate. Over 6,000m2 of new reinforced concrete roadways were constructed which provide access for HGV and drilling rigs around the site.
Installation of 2,830 linear meters of process pipework was required around the site to facilitate the new wellhead construction along with mechanical carbon steel terminations at the four new wellheads, providing a critical distribution network between extraction and processing infrastructure.
Additionally, a new concrete process chamber 10m x 9m x 3.5m deep complete with interconnecting carbon steel process pipework was constructed. Associated concrete anchor blocks were constructed to fix pressurised HPPE process pipework into place. Associated cabling works were included within the project whereby around 5km of HV & LV cabling was installed in and around the site to power the permanent brine drilling operations.
The site is situated within around 80 acres of arable and stock farmland tenanted to local farm businesses by INEOS Inovyn. Enablement works consisting of approximately 22,000m3 of topsoil stripped, bunded and managed on-site for re-use on completion of the civils and mechanical works, controlled under the monitoring of a qualified soil engineer, ensuring the protection and reinstatement of the site’s habitats and biosecurity.
The project was particularly challenging due to the complex nature of the works, where a multitude of skillsets including civils, mechanical & electrical was required to complete sections of work. Therefore, a collaborative approach with multiple subcontractor partners was required to ensure the completion of works in the correct sequence; a complex task that could only be completed with a one team approach from all contributors, delivered through regular collaborative planning sessions, ensuring that the sequenced works were carried out efficiently to mitigate delays whilst respecting the surrounding environment. A weekly 5-week lookahead programme was implemented along with weekly meetings to ensure effective communication was upheld, reiterating the need for sensitivity.
A weekly site tour was also arranged with the client Project Manager and our key delivery team so that communication regarding work progress was consistent and that any issues could be brought forward, and a solution devised as early as possible, with ongoing dialogue with client ecologists maintained throughout, ensuring a conscious awareness of the wildlife and impact our works would have. Bethell spent over 16 months on-site at Northwich, and in that time built excellent collaborative relationships with all partners; demonstrating Bethell’s core values throughout the delivery stage whilst aligning these with INEOS Inovyn’s Life Saving Rules.
This project was recognised with a Highly Commended Project of the Year award at the 2023 CECA North West Awards Evening!