COMPANY:
Engie

Duct balloons used as a moisture barrier to allow an extended lay-up period.

Duct Balloons are widely used worldwide in the mining and power generation sectors to isolate duct sections or stacks and facilitate maintenance.
Duct Balloons are widely used worldwide in the mining and power generation sectors to isolate duct sections or stacks and facilitate maintenance.

Back Ground

Duct Balloon
COMPANY:
Engie
LOCATION:
Kwinana Cogeneration Plant

Engie is a global energy company focusing on low-carbon energy solutions. In Western Australia, Engie operates the Kwinana Cogeneration Plant, a key Kwinana Power Station complex facility. The plant, owned by the Synergy Power Corporation, provides both electricity and steam, serving nearby industrial customers while contributing to the region’s energy reliability and sustainability.

Duct Balloon is used to protect gas turbine during temporary shutdown

Engie needed a solution to preserve the condition of a Gas Turbine during a temporary shutdown caused by reduced energy demand, allowing for an eventual restart with just 24 hours’ notice. To prevent corrosion by keeping the turbine warm and dry, Engie sought a cost-effective method to block airflow through the boiler’s exhaust stack. Giant Inflatables Industrial responded by designing and fabricating a custom duct balloon similar to those used in Combined Cycle Gas Turbine plants. This duct plug, deployed from the stack’s landing, provided an efficient and flexible way to maintain the turbine’s condition while minimising costs during the uncertain operational period.

A closer look

Inflatable Duct Cushion

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Background

Duct Balloon
COMPANY:
Engie
LOCATION:
Kwinana Cogeneration Plant

Giant Inflatables Industrial, known for its expertise in the mining, power generation, construction, and defence sectors, temporarily shifted focus to assist its sister division, Giant Inflatables, with an unprecedented challenge: building the world’s tallest inflatable airdancer. Leveraging its engineering capabilities, the team designed and fabricated a 50-metre inflatable tube man, overcoming complex technical and environmental hurdles. This collaboration demonstrated Giant Inflatables Industrial’s adaptability and commitment to delivering innovative solutions beyond its traditional industrial focus.

Unique Challenge

Giant Inflatables Industrial provided technical advisory and fabrication expertise to its sister division, Giant Inflatables, to engineer a 50-metre inflatable tube man for Amber Energy’s marketing initiative in Melbourne’s CBD. The project required precision engineering and innovative materials to overcome unique challenges.

Fabric Technology from a Different Sector

The team utilised spinnaker cloth, a material renowned in professional sailing for its exceptional strength-to-weight ratio to achieve the ideal balance of strength, flexibility, and lightweight properties. It was designed to endure high wind pressures and provided the durability needed to withstand continuous airflow stresses while maintaining the tube man’s dynamic motion. Its flexibility and resilience ensured stable performance and safety in Melbourne’s variable weather, showcasing the team’s ability to adapt advanced materials for innovative engineering solutions.

Custom Engineered Fan

A custom high-velocity fan was engineered and fabricated to meet the unique demands of the 50-metre inflatable tube man. Where standard fans lacked the power and precision required to maintain consistent airflow over such a large structure, engineers at Giant Inflatables Industrial designed a solution capable of generating a powerful, controlled air current that could keep the tube man fully upright, even in Melbourne’s variable wind conditions.

The fan incorporated high-strength materials to endure continuous operation and was equipped with advanced airflow stabilisation technology to prevent fluctuations that could cause instability. Its design also reduced noise, ensuring minimal disruption in the busy CBD environment. By balancing power, efficiency, and durability, the fan became a critical component of the project, ensuring the tube man performed reliably throughout the week-long campaign.

Testing occurred in Melbourne’s backcountry, where engineers assessed inflation safety, fan efficiency, and wind response. A smaller, 30-metre version was also developed for unfavourable weather scenarios.

Results

The Amberman debuted in Melbourne’s CBD, operated by Giant Inflatables’ team to ensure safe assembly and compliance with municipal regulations. The inflatable was activated during optimal renewable energy availability, symbolising Amber Energy’s commitment to sustainable practices. The week-long event, live-streamed and shared on social media, achieved widespread visibility and reinforced Amber Energy’s eco-friendly message.

Worlds tallest air dancer
The team used spinnaker cloth, a material highly regarded in professional sailing for its outstanding strength-to-weight ratio, to attain an optimal blend of strength, flexibility, and lightweight characteristics.
Worlds tallest air dancer
Giant Inflatables Industrial created a high-velocity fan that produces a strong, controlled airflow, ensuring the tube man remains fully upright, even amid Melbourne’s unpredictable wind conditions.
Worlds tallest air dancer
Testing occurred in Melbourne’s backcountry, where engineers assessed inflation safety, fan efficiency, and wind response.
Worlds tallest air dancer

A closer look

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