Ketton Ducting Replacement

Ducting Replacement at Ketton Works

Project Overview:

We recently completed a comprehensive ducting replacement project at Ketton Works for a valued client. This was a complex undertaking that required detailed planning, precise manufacturing, and efficient on-site work to ensure minimal disruption during the plant’s scheduled shutdown.

Scope of Works:

Survey:

Our team conducted an extensive survey of the existing ducting to confirm exact dimensions. While initial drawings were available, slight deviations were anticipated, and we adapted to these on-site, ensuring the new ductwork would fit seamlessly.

Design & Manufacturing:

We developed arrangement and manufacturing drawings to facilitate the off-site assembly of the new ductwork sections. The new sections were crafted using robust 16Mo3 material to withstand high-temperature conditions, meeting the operational demands of the plant.

Additional Components:

We supplied and fabricated two 850mm diameter cold air bleeds, complete with actuators and matching flanges. These components, also manufactured from 16Mo3, were designed to integrate seamlessly into the new ducting system.

Assembly & Installation:

Before the scheduled shutdown, we pre-assembled the new duct sections on-site to allow for a swift changeover. During the shutdown, our team worked 24/7 to remove the existing ductwork and install the new sections promptly. This approach minimised downtime and ensured the plant was back up and running on schedule.

Thermal Insulation:

Thermal insulation was crucial for the project’s success. We applied a 100mm thick, 130kg density mineral wool wire mattress, banded and covered with 0.9mm thick Aluzinc for maximum efficiency. Final coverings for the joints were completed post-changeover to ensure seamless operation.

Overcoming Challenges:

A key aspect of this project was managing the weather conditions, particularly the high winds we experienced during the installation phase. Our team prioritised safety at every step, carefully monitoring weather patterns to identify the optimal windows for lifting and installing the new ductwork. This meticulous approach ensured both the safety of our workforce and the successful execution of the project.

The Result:

The ducting replacement was executed with precision, safety, and efficiency, fulfilling our client’s requirements within the tight shutdown window. Our ability to adapt to on-site conditions and coordinate with weather constraints ensured a smooth transition to the new system, enhancing operational reliability for the client.

Contact Wright Engineering today to discuss your project.