Calciner Waste Heat Recovery Improvement
Washington
Industry
Energy
Services
Energy Efficiency & Emissions
Key disciplines
Civil/Structural
Electrical
Mechanical
Piping
Process
Project Management
Client Challenge:
The main focus of this project was to replace or improve the radiant, convection, and air cooler sections of the calciner to meet new calciner seismic code and regulations. This Calciner project also included reducing the risk of boiler tube failure and unplanned shutdown, improve unit reliability, and minimize expense associated with turnaround frequency and repair costs. Project challenges included eight critical lifts in a highly congested area of the two 86,400 lbs. radiant sections and two 96,600 lbs. convection sections.
Anvil Solution:
Our Anvil team helped the client execute an extensive seismic retrofit of the existing structure while the units were fully operational. This complex, multi-disciplined project involved temporarily relocating electrical and controls during the retrofit. By identifying the scope of the project early on, our team significantly reduced the planned turnaround time. The project involved replacing and reinforcing beams, plates, gussets, and the foundation to accept the new sections.
Our Anvil team collaborated extensively with the crane operators and owners to support the 3D animated modeling of equipment movement, timing, and relocation. We constructed a fully animated 3D model to analyze the eight critical lifts using two cranes and one 550T Mega wing crane. The 3D model, illustrating each lift radius, swing direction, hoist height and counterweight clearance was also checked in the field prior to the lifts.
Results:
Our team completed the project with zero safety incidents and engineering precision on all the critical lifts and fit-up of these four massive sections. Actual TIC was within 3% of the client’s budget and on schedule. This project was awarded the Northwest Construction Consumer Council’s (NWCCC) 2022 Distinguished Project Award—Best Private Project Over $10 Million and 2022 Safety Excellence Award.
Key Stats & Figures:
• Final TIC: $31.79 million
• Total Hours: 42,605
• OSHA Incident Rate: 0.0
• Lost Workday Cases: 0.0
Awards & Recognition:
Gallery
“Congrats on the Project Recognition NWCCC award. The award is thrilling. That was a fantastic project we executed. Thanks for all your support!”
Client, Project Manager