Customer: Isab S.r.l.

Site: Priolo Gargallo (SR)

Period: from March 10th, 2015 to April 23rd, 2015

207.000

MANHOURS

815

PEAK (PEOPLE)

General turnaround 2015 – Isab South Plants Refinery and Isab Energy Electrical Power Plant: Lots 1 and 4 – Vessel Plant 500 improvement efficiency – HRSG modification and Thermal Cycle for natural gas conversion – IGCC Plant – Vessel 700

The scope of work included the following activities:

Lot 1 (Units 200/300/400/200A desulphuration plants):

– Heat exchangers, air-fins maintenance and piping replacement (n. 83)

– Vessels maintenance (n. 14)

– Columns maintenance (n. 7)

– Equipments replacement (n. 6), culumns (40 tons) waterjet cutting and dismantling. Welding activities.

– Piping replacement, structures dismantling, prefabrication, assembling and new investments (80.000 kg)

– Pressure Equipment Directive and D.M. 329  implementation (n. 34)

– Non-destructive testing

– Bolt tensioning

– Pre-commissioning activities and start-up assistance

Lot No. 4 (Sulphur, SWS, Gofiner, Ammine Rigenerator, Utilities, Torch, Units 700A/110/1200/1400/2200/2300/2400/2600):

– Heat exchanger, air-fins maintenance and piping replacement (n. 52)

– Vessel maintenance activities (n. 50)

– Columns maintenance (n. 5)

– Reactors maintenance activities (n. 7)

– Heaters maintenance (n. 9)

– Sulphur tank maintenance activities (n. 3)

– Heater burner replacement

– Sulphur tank replacement

– Heat exchangers, valves 38″ and column replacement

– Piping replacement, dismantling, prefabrication and assembling activities and piping/structures new investments (160.000 kg)

– Scaffolding activities

– Insulation activities

– Industrial cleaning

– Electro-instrumental activities

– Civil works

– Refractories activities

– Bolt tensioning

– Painting

– Non-destructive testing

– Pre-commissioning and start-up assistance

– Pressure Equipment Directive and D.M. 329 (n. 54)

HRSG, thermic cycle Turn-Key modifications and maintenance activities (Isab Energy Power Plant):

– execution design

– Materials supply

– Testing and inspection

– New investments activities:

  • Post-combustion system modifications following the switch from syngas to natural gas

  • HPECO By-pass modification

  • Drainage system modification, consisting in valves replacement

  • Stack Insulating Damper installation

Maintenance activities:

  • Safety beams replacement with upgrade AISI material

  • Operability steam generator control in compliance to ISPESL n. 48/2003

  • Manifolds INAIL reparation

  • Pre-commissioning

  • Commissioning

  • Start-up assistance

  • Test-run

Heater Reforming Plant (500):

– Convective coils (500-F-105) complete replacement: dismantling of existence coil, refractories replacement, tube plate substitution, installation of new coils (n. 224 tubes – diam. 4″ – length 30 m)

– Chemical cleaning of new convective coils (500-F-105)

– Radiant cellar replacement (500-F-104) n. 45

– Vessel manifolds replacement (500-F-101÷105) – diam. 24″ – length 10 m

– Water pumps replacement (n. 2)

– Booster F-301/302 complete paneling and wall refractory replacement

– Heaters 500-F-101÷104 and F-301/302 complete replacement  of main supply

– Piping dismantling, prefabrication and replacement (30 tons)

– Piping pressure test

– New shutter installation

– Heaters (500-F-101÷104 and F-301/302) external and internal maintenance

– Carpentries modification and reinforcement activities

– Refractories replacement activities

– Instrumentation replacement/installation

– Complete painting of casing heaters 500-F-101÷104 and F-301/302

– Scaffolding, assistance and auxiliaries works

– Insulation activities

– Environmental monitoring

– Non-destructive testing and thermic treatments

– Pressure Equipment Directive and D.M. 329  implementation (n. 14)

New Heater Gofiner Turn-key installation (Plant 700):

– Execution design

– New processing heater supply and installation with temperature of 660 °C, pressure 66,5 bar, thermic power 34.000 W/m2, including of:

  • test and inspections

  • heater’s metallic structure

  • refractories

  • coils

  • burners with accessories

  • conduits

  • Air Ventilators (No. 2)

  • Re-circle emission ventilator (No. 1)

  • Automatic shutters emission and air

  • Emission and air conduits mechanical structures

  • Complete APH, accessories included

  • Flame control panel

  • Instrumentation and oxygen analyzer

  • Carriage

  • Assembling

  • Non-destructive testing

  • Insulation activities

  • Painting

  • Electro-instrumental activities and connection activities to DCS system

  • Pre-commissioning

  • Commissioning

  • Start-up assistance

  • Test-run