The Kemper IGCC

Project Description

Kemper Project produces cleaner energy through the use of integrated gasification combined cycle (IGCC) and carbon capture technologies, eliminating the majority of emissions normally emitted by a traditional coal plant. Because the activities involved with an IGCC plant involve minimal water consumption, these processes will not harm the water sources of the area.

The project scope handed down to Sanria engineering involved structural steel connection design, structural steel detailing, preparation of 3D models, shop drawings, erection drawings and CNC files for automated fabrication for the Gasifier Structure, Coal processor, Cooling Structure, Pipe support structures, grating and access platforms. The estimated structural steel quantity was 26,000 tons.

The main challenge for our customer was to ensure extreme coordination of all disciplines and the size of the structures made it mandatory to design, detail and deliver in several sequences of shop drawings. Our expert team at Sanria had taken time and effort to decipher the contract documents and communicate with the Customer of any missing information or required data to begin the task at hand. The engineers coordinated the efforts and design reviews with various other contractors and ensured the job moved in smoothly as per planned schedules.

A total of 77 sequences was established to feed the proposed schedules and the engineers worked closely with fellow contractors to mitigate any clash or field related issues during detailing phase to ensure no field RFI’s existed. A job of this magnitude required constant information flow between our office and the Customer and through weekly updates and email communications. Additional attention was paid to coordination locations between the sequences to ensure the drawings reflected the most accurate details for tie ups between installed sections of the structures and newly erected modules of the structure.

The Steel structure was divided into 4 major sections. Lower Gasifier, Middle Gasifier, Upper Gasifier and Coal Processor. We have to do internal coordination between gasifiers and adjacent Coal process structure.

We had Jumbo columns in this project from sizes 14x550 and 14x733 spanning multiple tier elevations along with huge Plate girders in the Middle Gasifier.

Our fabricator used multi spindle drilling equipment to simultaneously drill in one feed.

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