This project involved the fabrication and installation of a new 6” gas main to supply a new gas booster, tying directly into pre-existing pipework. While installing new pipework in isolation is straightforward, integrating into an existing system presents a different set of challenges – particularly where layout, elevations, and fixed connection points cannot be altered.

Scope of Works

Kee Engineering completed the full scope from measurement through to installation, including:

• Survey and setting out of existing pipework and connection points
• Workshop fabrication of new 6” pipe spools with flanged connections
• On-site installation and tie-in to the existing gas main
• Installation of new pipe supports fixed to the existing structure

Integrating with Existing Pipework

Existing pipework is rarely installed with future modifications in mind. Over time, systems evolve, space becomes restricted, and alignment tolerances tighten. In this case, the existing pipework dictated the final connection position, elevation, and orientation.

Rather than forcing a misaligned connection or introducing unnecessary stress into the system, our team adjusted the new pipe route using 45° bends. This allowed the new gas main to transition cleanly into the existing run while maintaining correct alignment, flange face orientation, and support spacing.

Careful fabrication ensured that spool lengths, angles, and flange positions matched the surveyed dimensions, reducing the need for on-site adjustment and ensuring a controlled installation.

Installation Approach

The pipework was installed in sections to allow accurate positioning and controlled fitting. Supports were installed to suit the existing steelwork, ensuring the new gas main was restrained correctly and remained serviceable for inspection and maintenance.

Throughout the works, the focus was on achieving a clean, practical installation that respected the constraints of the existing system while delivering a reliable new supply for the gas booster.

Final Result

The completed 6” gas main was successfully integrated into the existing pipework, providing a robust, well-aligned connection ready for commissioning. This project demonstrates Kee Engineering’s ability to adapt new installations to legacy systems, delivering precise pipework solutions where conditions on site leave little room for compromise.