Located on
the coast north of Kuala Lumpur,
Manjung Thermal Power Plant is the
largest of its kind in Malaysia.
The new facility has three identical
700MW coal-burning boilers and in November
2007 a new Instant boiler access system
was commissioned on site by Instant Scaffolds
Malaysia with technical supervision provided
by Instant UpRight. For Instant UpRight,
this was the largest boiler project undertaken
to date, requiring five 40ft containers
of product to ship the complete system from
the company’s manufacturing plant in
Park West.
The
Structure Manjung’s
main boiler system consists of
three core elements – Base Structure,
Main Structure and Super-heater
Towers. Combined, they give an
overall working height of 72m
and reach as far as the boiler
ceiling. The structure is made
up of the following:
Extra-heavy-duty Snapout
Towers. Each tower is 44m high and is
supported by an 11m high base structure.
Spandeck Walkways used to
bridge the Snapout Towers around the boiler
internal perimeter. Each walkway is in
excess of 80m long.
Special custom-designed cantilever
platforms which give access to the corners
of the boiler where the burners are
located.
The
fully platformed area at the top of the
main structure is 400 square metres (the ‘dance
floor’) requiring the use of 100 Spandecks.
It is used to support the 15m high Span 400 towers
which give access to the super-heater area
of the boiler.
High
Utilisation
As the Manjung Power Plant has only
recently come into service, it is planned
to overhaul each boiler once every two years.
Therefore over a two year period, the full
system will be installed three times and utilised
for up to two months each time. In addition,
several emergency shutdowns of short duration
can be anticipated each year.
Apart from planned shutdown periods
for comprehensive boiler overhaul work, the
Instant UpRight Boiler Access system will also
be used in response to emergency
shutdowns, providing safe and rapid access
to the affected area of the boiler. This has
already occurred at least once since the
boiler scaffold was first commissioned
in November 2007. A partial installation
of the boiler scaffold was used to access
one corner of the boiler at a height of around
30m.
Time
Saving Solution
Future installations should be completed in
60 working hours (4 days with 2 x 8 hour shifts)
which represents a very significant reduction
in boiler downtime compared to traditional
steel scaffold systems. Local operatives have
been given instruction from Javen Hoo and Eric
Kogulan of Instant Scaffolds Malaysia and Technical
supervision was provided by John Damery of
Instant UpRight.
Win
a digital SLR camera when you send in your ‘Instant
Application’ photographs!
Simply send in your application photographs
(resolution must be a minimum 300dpi) plus
a 300 word description and have the chance
to win a quality Digital SLR camera.
Competition
Rules:
The competition is open to
all Distributors, Dealers, Agents and Customers
of Instant UpRight Ltd
The competition will run
from 1st March to 1st October 2008
The winning photograph will
be selected by the Instant UpRight sales
and marketing department and their decision
will be final and binding
The winner of the best application
photograph will be announced on 2nd October
2008 at the Instant UpRight BBT Summit in
Ireland
The winning photograph will
be published on the Instant UpRight website
during October 2008
The photographs must be a
minimum 300dpi and be available for use freely
in all Instant UpRight promotional material
The
fully platformed area at the top of the
main structure is 400 square metres (the ‘dance
floor’) requiring the use of 100 Spandecks.
It is used to support the 15m high Span 400 towers
which give access to the super-heater area
of the boiler. 
Apart from planned shutdown periods
for comprehensive boiler overhaul work, the
Instant UpRight Boiler Access system will also
be used in response to emergency
shutdowns, providing safe and rapid access
to the affected area of the boiler. This has
already occurred at least once since the
boiler scaffold was first commissioned
in November 2007. A partial installation
of the boiler scaffold was used to access
one corner of the boiler at a height of around
30m. 
