Gas Turbine Air Inlet Filter Support Structure

As part of Ireland’s first large-scale power station designed to operate on sustainable biofuels, the project required the delivery of a substantial 56-tonne steel structure within a challenging marine environment on the Shannon Estuary. The works formed a critical element of the new 300MW peaker plant, which will play a vital role in strengthening Ireland’s energy security, supporting grid stability, and facilitating the transition to a lower-carbon electricity network through the integration of renewable energy sources.

The project demanded exceptional engineering expertise, meticulous planning, and close collaboration between KME, Atlantic Projects Company (APC), and SSE to safely deliver a highly complex structure under demanding fabrication, transportation, and installation conditions. From early-stage design development through to final delivery, KME’s involvement was instrumental in ensuring the project achieved its technical, quality, and programme objectives.

Project Journey, Challenges Overcome & Innovative Solutions

KME was contracted by Atlantic Projects Company (APC) to transform the client’s conceptual design into detailed construction drawings, before undertaking the fabrication, protective treatment, transportation, and installation support of the 56-tonne steel support structure.

From the outset, the project presented a series of technical and logistical challenges. As a key component of a nationally significant energy infrastructure development, the structure had to meet stringent quality, safety, and durability requirements while adhering to a demanding project programme. The project team worked closely with APC and SSE throughout the design development phase to optimise constructability, streamline fabrication processes, and ensure seamless integration with the wider power station development.

The sheer scale of the structure introduced considerable complexity. Standing approximately 12.5 metres high and comprising 56 tonnes of structural steelwork, the support frame was designed to accommodate substantial operational loads while maintaining strict dimensional tolerances. Individual columns and structural members weighed up to 4 tonnes each, requiring detailed lifting studies, specialised handling procedures, and carefully planned fabrication sequences to ensure safe and efficient manufacture.

One of the most significant technical challenges involved the corrosion protection system. Located on the shores of the Shannon Estuary, the structure would be exposed to a highly corrosive marine atmosphere throughout its operational life. To provide the required long-term durability and minimise future maintenance requirements, the entire structure was specified to receive a double-dipped galvanised finish. Achieving this standard required extensive planning during both the design and fabrication stages, including the incorporation of suitable venting and drainage details, strategic component segmentation, and close coordination with the galvanising contractor to ensure complete coating coverage across all elements of the structure. This approach delivered a robust corrosion protection system capable of withstanding the harsh environmental conditions expected over the asset’s lifespan.

Transportation of the completed steelwork presented another major challenge. Several primary beam sections measured up to 12.5 metres in length, classifying them as oversized loads for the Galvanising at Shannonside and requiring comprehensive logistics planning. Deliveries were carefully sequenced to align with site installation activities, reducing storage requirements and supporting efficient project execution.

The installation phase demanded an equally high level of planning and coordination. Situated adjacent to the River Shannon, the project site imposed operational constraints relating to ground conditions, weather exposure, and crane positioning. KME provided installation support and worked closely with site. The assembly of large structural components at height required precise coordination between fabrication tolerances, lifting operations, and site construction activities to ensure successful installation.

Throughout the project, KME leveraged advanced 3D modelling, detailed fabrication planning, and rigorous quality control processes to mitigate risks and maintain accuracy. Regular collaboration with APC, SSE, and professionals enabled proactive problem-solving and ensured challenges were addressed before they could impact programme or performance.

The successful completion of the Gas Turbine Air Inlet Filter Support Structure demonstrates KME’s capability to deliver complex heavy steel projects in demanding environments. By combining technical expertise, innovative engineering solutions, and strong project management, KME successfully overcame significant fabrication, corrosion protection, transportation, and installation challenges to contribute to one of Ireland’s most important next-generation energy infrastructure developments. The project stands as a testament to KME’s commitment to quality, safety, and engineering excellence in the delivery of critical national infrastructure.