Client Site: Keadby Power Station
Fabrication Contractor: Multiweld UK
Services: Reverse Engineering Support, 3D Modelling, Detailed Fabrication Drawings

Amrose Associates was engaged to support reverse engineering works at Keadby Power Station involving a major exhaust silencer within the power generation system.

The silencer plays an important role in controlling and reducing noise as exhaust gases move through the plant, helping support both operational performance and environmental compliance.

With no original drawings available, the project involved capturing the geometry, internal configuration and fabrication details of the existing unit so that a replacement silencer could be accurately manufactured.

The challenge

The lack of legacy design information posed both technical and commercial risk. Without an accurate fabrication record, any further replacements in the future would require similarly complex and disruptive dismantling and measurement.

The exhaust silencer was a complex steel assembly with multiple internal components, requiring detailed survey work, engineering modelling and fabrication expertise to produce accurate, buildable documentation.

Our role involved:

  • Accurately measuring the dismantled steel structure
  • Recording and understanding the internal noise control design
  • Producing detailed drawings ready for manufacture
  • Supporting the long-term maintenance and replacement of the asset

Our approach

We developed a fully coordinated 3D model of the exhaust silencer based on measured survey information and fabrication input. This model was then used to generate a comprehensive suite of detailed fabrication drawings, including:

• General arrangement drawings
• 3D component views clearly illustrating internal configurations
• Full detailing of plates, stiffeners and baffle arrangements
• Sections, weld details and fabrication notes suitable for direct workshop use

The outcome

The final drawing package provides a complete digital record of the component, allowing future replacement units to be manufactured directly from the drawings.

This gives the asset owner:

  • Improved cost certainty for future procurement
  • Reduced programme risk during outages
  • Enhanced asset resilience and maintainability
  • A documented basis for any future design improvements

In practical terms, the work has converted a one-off reverse engineering exercise into a repeatable manufacturing solution for more efficient lifecycle asset management.

If you are planning replacement, refurbishment or reverse engineering works within the power or industrial sectors, Amrose Associates can provide clear, accurate and buildable engineering documentation to reduce risk and improve cost certainty.

Ask Amrose. Call 0113 418 0694 or email enquiries@amroseassociates.com