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┬á┬á

• Delays in delivery of key components including concrete supply due to peak demand,┬áimpacting┬áon the sequencing of works┬á

• Restricted site access from a busy main road, limiting┬álogistics┬áand material deliveries┬á

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

Solution

• Adapted the delivery┬áprogramme┬áand redesigned works to allow multiple concrete pours within the same day, mitigating supply delays without┬áimpacting┬áoverall progress┬á

• Maintained close coordination with subcontractors, ensuring clear communication of delays and regular┬áprogramme┬áreviews to adjust sequencing┬á

• Implemented enhanced temporary works management, including I-Rod pipe supports, redesigned formwork systems, excavation┬ásupport┬áand strict┬ápermit┬ácontrols┬á

• Delivered high-integrity stopple operations alongside golden weld┬ámethodology┬áin deep excavations, using controlled gas environments and robust SCO procedures and RAMS┬á

• Undertook fabrication,┬áassembly┬áand testing of PRS stream spools,┬ámanifolds┬áand heat exchanger vent systems, supported by hydrostatic and pneumatic pressure testing┬á

• Completed E&I upgrades, including installation of ducts, structured cable routing,┬áinstrumentation┬áand stainless-steel impulse lines┬á

• Strengthened project governance through early warnings, regular coordination┬ámeetings┬áand phased scheduling across all disciplines┬á

Outcome

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

• Achieved high-integrity fabrication outcomes,┬ávalidated┬áthrough comprehensive hydrostatic and pneumatic testing regimes┬á┬á

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

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

• Implemented effective site security and traffic management throughout┬á