Project overview
Following a fire at Uniper’s Connah’s Quay site, the original Hydrogen Compound Heater Gas Control CO₂ Antifreeze Panel was completely destroyed. With no available design drawings and obsolete original parts, J&P Group was tasked with delivering a full design, build, installation, and commissioning of a replacement control panel.
The Challenge
- Fire Damage – Original panel destroyed beyond repair.
- No Design Documentation – No existing CAD drawings or wiring diagrams.
- Obsolete Components – Original parts unavailable and required modern replacements.
- Reverse Engineering – Functionality had to be worked out from limited site information.
Project Goals
- Reverse engineer and design a new replacement panel.
- Source modern equivalent components.
- Build, test, and deliver a fully functional panel.
- Install and commission on-site to Return to Service (RTS).
Our Approach
The project required a multi-disciplinary team, including a Design Engineer, Electrical Technician, and Instrumentation Technician.
- Design & Reverse Engineering
- From client input on operational requirements, J&P engineers created a functional design.
- New CAD drawings were produced to document the replacement system.
- Panel Build & Workshop Testing
- The panel was built in J&P’s workshop using modern components.
- Full pre-installation testing was carried out to ensure functionality and reliability.
- On-Site Installation & Commissioning
- The new panel was delivered and mounted onto the repaired framework in the hydrogen compound.
- Electrical connections were completed by J&P’s EC&I team.
- The system was commissioned and returned to service successfully.
Outcome
- Fully operational replacement panel, built and commissioned without original design data.
- New CAD drawings provided to the client for future maintenance and reference.
- Obsolete parts replaced with modern, reliable components.
Successful RTS delivery, ensuring critical system functionality at Uniper Connah’s Quay.
This case study highlights problem-solving, engineering expertise, and successful delivery under challenging conditions.