Case Studies

Delivering a Complex AGI Capacity Upgrade in Maltby

Challenge

• Introduction of a new IAMS assurance process mid- project requiring changes to assurance procedures and subcontractor briefings  

• Delays in delivery of key components including concrete supply due to peak demand, impacting on the sequencing of works 

• Restricted site access from a busy main road, limiting logistics and material deliveries 

• Coordination of multiple workstreams, including stopple operations, fabrication and E&I installs within live gas environment

Solution

• Adapted the delivery programme and redesigned works to allow multiple concrete pours within the same day, mitigating supply delays without impacting overall progress 

• Maintained close coordination with subcontractors, ensuring clear communication of delays and regular programme reviews to adjust sequencing 

• Implemented enhanced temporary works management, including I-Rod pipe supports, redesigned formwork systems, excavation support and strict permit controls 

• Delivered high-integrity stopple operations alongside golden weld methodology in deep excavations, using controlled gas environments and robust SCO procedures and RAMS 

• Undertook fabrication, assembly and testing of PRS stream spools, manifolds and heat exchanger vent systems, supported by hydrostatic and pneumatic pressure testing 

• Completed E&I upgrades, including installation of ducts, structured cable routing, instrumentation and stainless-steel impulse lines 

• Strengthened project governance through early warnings, regular coordination meetings and phased scheduling across all disciplines 

Outcome

• Successfully installed and supported commissioning of rebuilt PRS streams, upgraded pre-heat systems and new outlet pipework  

• Achieved high-integrity fabrication outcomes, validated through comprehensive hydrostatic and pneumatic testing regimes  

• Effectively mitigated supply chain delays and scheduling pressures with no significant impact on the overall programme  

• Delivered a safe, coordinated upgrade within a constrained and high-risk operational environment  

• Implemented effective site security and traffic management throughout