How A Bespoke Scaffolding System can Transform Boiler Access & Response Times

February 25, 2015

Bespoke Scaffoding Systems Energy IndustryIn the past, erecting a bespoke scaffolding system for boiler access in the energy industry was a time and resource heavy process. Commonly, boiler installations could easily take 10 or 11 days to erect, given the time taken to assemble access towers. In a sector where down-time costs could be in the region of £125,000 per day, this represented a major challenge for the industry and had considerable cost implications for all involved. However these days quick-assembly aluminium access solutions are available to significantly cut down on labour and time requirements. People in the industry are waking up to this fact, and have been turning to Instant Upright as the market leader in custom access solutions – whether it’s a boiler access system or more general access solutions for a project or facility. Customers also take confidence from the fact that Instant Upright offers expert support and we can supply full engineering calculation sign off, when requested to do so.

Recently we’ve been heavily involved in a number of high-profile projects in the energy industries, and in each case we delivered a bespoke scaffolding system to meet the needs of the business.

Manjung Thermal Power Plant

Situated in Kuala Lumpur, Malaysia, Manjung Power Plant is the largest of its kind in the region. In November 2007 Instant Upright was commissioned to oversee the implementation of a new boiler access solution to service the three 700mw boilers on the premises. This was a huge project for everyone involved and it required us to ship five 40 foot containers to transport our product to Asia.

To maintain plant efficiency, each boiler needs to be completely overhauled once every two years. In addition, any solution had to be capable of rapid assembly to respond to any emergencies that may arise. Finally, each boiler required a platform with a working height of 72m. The boiler access solution we provided met these requirements admirably, and included the following components:

  • 44 metre snap-out towers, resting on an 11 metre tall structural base. Our quick-erect towers consist of interlocking 2 cubic metre modules which fold into a one-piece bundle. They can be expanded in seconds to form a rigidly braced tower access tower.
  • Elevated walkways comprised of Spandeck units, which are used to span the gap between the snapout towers around the boiler perimeter.
  • A platformed area at the top of the structure measuring 400 metres squared, comprised of one hundred Spandeck units.

Contrasting with any traditional steel bespoke scaffolding system, this lightweight aluminium boiler access solution can be assembled in a mere sixty working hours, significantly cutting down on system downtime at the plant.

Sipat Power Plant

The Sipat Power Plant facility is located in Chhattisgarh, Central India. The challenge posed by this project was to provide access to the plant’s three identical 660mw units, which are 73m high, 18.8m wide and 18.1m deep. To address this, a custom Quick-Erect boiler access system was manufactured and subsequently implemented at the plant.

Like the Manjung project, our Snap-Out towers were used extensively throughout this project, as they can provide easy access through standard boiler access manholes. Nine 40 metre modules were used in total, traversed by Spandeck walkways to offer access to the plant’s four waterwalls. A “Dancefloor” platform was installed just beneath the hanging panels of the division superheater, which could be accessed using seven 21 metre Quick-Erect towers.

Thanks to its streamlined design and aluminium alloy frame, the whole bespoke scaffolding system weighs a mere 48 tons. Construction time is further reduced as there is no requirement for assembly tools, as the whole frame is supported on structural truss beams custom made to fit this purpose.

Come to Instant Upright for all your boiler access needs

The successful delivery of these products attests to the fact that there is no job too big for Instant Upright to take on. With over sixty years of providing bespoke boiler access solutions to the energy market, we know exactly what we’re doing when it comes to boiler access solutions. Get in touch today to find out more about our offerings.