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Hexcel Composites UK

Hexcel Composites UK

    • Client:
    • Hexcel Composites, Duxford, Cambridgeshire, UK
    • Consultant:
    • Fluor Corporation, Farnborough, UK
    • Project Description:
    • A new resin manufacturing process
    • Work-Scope:
    • Mechanical HVAC, piping services, electrical and instrumentation works, design of all mechanical HVAC and electrical lighting and general services
    • Value:
    • £5.5M

Project Description

Brief Description

Kirby worked in close cooperation with Fluor Corporation to progress a new resin manufacturing process for Hexcel Composites from the design/budgetary stage through to construction and subsequent handover.

Design Capability

As part of the delivery team, Kirby was responsible for the design of all mechanical HVAC and electrical lighting and general services. We also provided design development input into Fluor Corporation’s overall process design scheme and partook in integrated planning sessions to develop the overall master build programme. Kirby was also responsible for the installation of all the above services including the design and installation of an FM-rated sprinkler system.

Understanding Client Needs

Piping systems catered for utility, wet and dry powder process systems and necessitated full traceability and NDT due to solvent and hot oil fluid presence. There was 4,500m of pipework installed across varying material grades. We were also responsible for the installation of all utility equipment and the provision of site services to primary process equipment including reactors, coaters and extruders.

Customer Satisfaction

This significant project for Kirby demonstrated our full-service capability and our ability to work closely with construction partners from early stage project concept through to construction and final handover. The original project was commissioned in 2011 and we were subsequently retained by the client and Fluor Corporation to replicate our scope of supply on an additional resin production process in 2014, again on a target cost contract basis.

Overcoming Challenges

One of the key challenges on this project was the unpredictable nature of deliveries of key plant items which were integral to the process. Kirby worked closely with the third-party vendors to ensure all support services were in place before these plant items were delivered, so as to minimise site interface works. This involved the pre-fabrication of several mock-up kits to enable process pipework systems to be routed as close as possible to their final positions in advance of equipment installation.

Through adopting this proactive engaged approach with our project partners we were able to maintain overall project schedule thereby facilitating the commencement of wet commissioning as planned.