GI Updates

JSPL - Heat Isolation Duct Plug

Engineering Expertise: Isolating Asia's Largest Foundry Duct at JSPL, Angul (India)

I. The Client Challenge (The "Why")

Giant Inflatables was commissioned by JSPL (Jindal Steel and Power Limited), Angul, Orissa, to engineer a rapid, high-temperature isolation solution for a critical ducting system in Asia’s largest single-location steel foundry.

The challenge was unique and highly technical:

• High Operating Temperature: The isolation plug needed to operate reliably in a duct environment with a sustained wall temperature of 800°C.
• Complex Access: The engineered cushion had to be flexible enough to fold and fit through a narrow 1200mm diameter access hatch, yet robust enough to inflate to a massive size and maintain seal integrity.
• Mission-Critical: Failure was not an option, requiring redundant inflation systems and guaranteed material performance.

II. GI's Engineered Solution (The "How")

Our in-house design and engineering team developed a composite isolation plug specifically for this environment. This solution goes far beyond standard inflatable products, proving our deep technical Expertise.

• Composite Construction: To manage the extreme temperature and achieve safe sealing, we utilized a twin-layer system:
• Dimensional & Access Design: The final cushion was designed at a 1200mm thickness and engineered with precise folding points to ensure successful deployment through the limiting 1200mm access hatch.

• Constant Air Redundancy: The plug uses a constant air fan feed system, powered by two externally placed, 1.5 HP fans (one main, one backup). This redundancy guarantees continuous pressure maintenance for operational safety.
• Anchoring: Robust Stainless Steel anchor/orientation points were integrated to allow for precise positioning and secure bracing inside the duct.

III. Transparency and Trust (The “Proof”)

Our commitment to quality on this mission-critical project included:

• Full Documentation: Providing initial design-to-supply duct drawings, material specifications, and detailed operating procedures (developed in consultation with the JSPL team) prior to production.
• Compliance: Ensuring all materials and electrical components (220/240 V fans) met required industrial standards for a secure and long-life application.

IV. Conclusion

The success of the JSPL isolation plug project demonstrates Giant Inflatables' capacity to deliver advanced, high-performance inflatable solutions for the most demanding heavy industrial and defense applications. We don't just supply inflatables—we engineer solutions.