ELK delivered a targeted mechanical repair package at Ince Park Renewable Energy, a 21.5MWe waste wood gasification facility capable of processing up to 176,000 tonnes of waste wood per year. The site uses Outotec Gasification technology to produce syngas, which is combusted to raise superheated steam for a Siemens steam turbine, exporting electricity to the District Network Operator.
The plant is operated and maintained by Evero Energy Services Ltd (EESL) on behalf of the asset owners Ince Bio Power Limited (IBPL). ELK worked closely with Evero to complete critical tube repairs during the site’s planned major outage window.
The challenge
As part of statutory inspection obligations under the Pressure System Safety Regulations (PSSR), the gasifier’s Vapour Space tubes were scheduled for Non-Destructive Testing (NDT). The gasifier contained 124 Vapour Space tubes, each approximately 12 metres long, manufactured to 3” Sch 80 SA-106B specification.
Historical inspection data and operational experience had identified wall loss in multiple locations, most commonly around tube bends (though not limited to them). The outage plan therefore anticipated the need for sectional replacements once the final NDT results confirmed the extent of repair.
ELK’s scope of work
During the outage, the gasifier was scaffolded and the relevant areas were prepared for inspection. Following grit blasting and NDT carried out by specialist partners, ELK completed the replacement of Vapour Space tube sections where defects and wall loss exceeded acceptable limits.
ELK’s work included:
- Cutting out affected tube sections identified through NDT findings
- Installing replacement tube inserts (bends and straights) in the required locations
- Completing weld repairs to the required quality standard and inspection hold points
- Working safely under strict confined space controls and permit conditions
A maximum of 50 inserts had been anticipated for completion, and ELK resourced the job accordingly to ensure programme certainty during the outage period.
Delivery approach
To meet outage constraints and ensure rapid turnaround between inspection results and repairs, ELK operated on a 24/7 delivery basis using trained and competent personnel. The team mobilised with the necessary tools, welding equipment, and consumables, and worked in step with the outage plan to avoid clashes with parallel activities.
Given the nature of the work inside the gasifier, ELK also provided the required confined space support, including:
- Hole watchers / top men for confined space entries
- Coordination with site rescue and control-of-work teams
- Strict adherence to Evero’s site HSE standards for working at height, lifting operations, RPE/PPE, confined space entry, and hot works
Collaboration on site
The project depended on close daily coordination between multiple parties. ELK worked alongside:
- The Evero Outage Team
- Evero Operations
- The NDT contractor responsible for inspection and defect mapping
This ensured that findings were translated quickly into actionable repair locations, and that repairs were completed efficiently without compromising safety or quality.
Outcome
ELK successfully delivered the Vapour Space tube replacement works as part of the planned major outage, supporting Evero and IBPL in completing PSSR-led repair requirements and returning the gasifier to service with integrity-critical sections renewed.
The project demonstrated ELK’s capability to execute complex repairs in high-control environments—balancing outage schedule pressure, confined space constraints, and strict quality expectations—while integrating seamlessly with site operations and inspection teams.