Energy & Decommissioning

Keadby 2 Power Station

  • project value £3.5 million
  • project completion 2021
  • project modularisation and OSM 90%

Keadby 2 is an 840MW combined cycle gas turbine (CCGT) power plant. It is one of the cleanest and most efficient gas-fired power stations in Europe and generate power through a natural gas-fired CCGT with an output of up to 910MWe. Keadby 2 generate reliable energy enough to power 840,000 homes.

Project Brief

The scope of work at Keadby 2 incorporated extensive use of Exyte Hargreaves’ Manufacturing facility in Bury for off site assembly and modularisation. This achieved supply of a modularised plant room, housing the Low Pressure Hot Water (LPHW) heating system and Building Management System (BMS):

  • Engineering, Procurement & Construction Contract.
  • Contractor Design Portions for specialised elements
  • Smoke Control System
  • Natural ventilation system
  • Intake units (Silencer + Motorized dampers)
  • Recirculation Fan Systems
  • Building Management Systems
  • LPHW heating system
  • Electrical heating systems in remote buildings

DfMA and Modularisation at Keadby

It was clear early on that Modern Methods of Construction (MMC) would facilitate the build time, accuracy and delivery against programme. There was a high component demand within a constrained working environment. A workable off site solution was ideal for our client’s requirements.

One of the major elements in the delivery of the project was the manufacturing efficiencies achieved by utilising offsite technology and methodology. Incorporating standard production techniques such as just-in-time delivery together with digital solutions providing the means of viewing the as-built needs via Augmented Reality enabled the team to deliver the project to suit the client’s needs.

MMC from Design to Installation

A key aspect of the design process was the use, and further development, of standardised digital components. These enabled a high degree of comfort at pre-manufacturing but also for future use as part of the continuous improvement of the library of parts (including pre and post construction data).

Speed of installation increased significantly by delivering the solutions within a modular frame. Delivery to site using this form of offsite construction not only enabled a high level of as-built on delivery, but also ensured fit for purpose due to the vast amount of build being developed within the framework.

Navigating the COVID-19 pandemic

Constructing the project using off site manufacturing techniques also had an impact of care during the COVID-19 pandemic. Our teams continued to work during this pandemic period by implementing strict safety protocols.

We held continuous safety briefings to ensure the project was completed safely and to the client’s project deadlines. Implementing such methods on a traditional production site would have been significantly harder. The simple act of working in a factory with strict health regimes and protocols was critical during this period.

"When the project went live there was a real sense of pride and achievement. Delivering Keadby 2 during a pandemic was a real challenge. All working methods were adjusted to allow for social distancing. Coordination and working relationships were also more difficult. Many years later it’s great to see this project completed and operating as one of the most efficient gas-fired power stations in Europe"

Levi Wilson

Project Manager


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