London Luton Airport required an upgrade to the backup power system supporting its baggage handling plant.

The existing 500kVA backup generator had been in operation for more than 40 years. Although it remained functional, the airport recognised the need to replace the ageing system to reduce the risk of future issues that could affect passenger movement, baggage distribution and arrivals processing.

P&I Group worked with the client and consultants to review the site requirements, agree the best delivery approach and plan the replacement works around the operational constraints of a live airport environment.

The generator supported a crucial area of airport infrastructure, where reliable standby power was essential to help maintain passenger, baggage and arrivals operations during a mains power failure.

The existing generator was located in a second-floor plant room within the main building, making removal and replacement more complex than a standard external generator installation.

The works also had to be delivered without disrupting the continuous use of a busy airside access road, which was needed by essential site vehicles. This required careful planning, coordination and site management to maintain safe access throughout the project.

P&I Group developed a detailed delivery plan to safely remove the existing generator and install the replacement system while keeping the airside access route available.

The new generator was positioned and connected to the existing bulk fuel tank. It was also integrated with the new LV switchgear to support the updated electrical infrastructure.

A ground-level connection point for remote load bank testing was installed as part of the works. This allows routine testing to be carried out more conveniently and with less disruption to site operations.

P&I Group’s scope included design support, project management, mechanical and electrical installation, delivery, off-loading, positioning, construction, commissioning and ongoing maintenance support.

The completed generator upgrade provides London Luton Airport with a more robust and reliable backup power system for its baggage handling plant.

By replacing the ageing 500kVA generator, the airport has reduced the risk of future power resilience issues affecting key operational areas. The new remote load bank testing connection also supports easier ongoing testing and maintenance.

The installation is supported by a comprehensive P&I Group maintenance package, giving the client long-term confidence in the performance and reliability of the system.