Project Overview
Client: Site Technology / Chekka Cement Plant
Location: Chekka, North Lebanon
Project Type: Combined Cycle Piping Installation (Industrial Power)
Year of Execution: 2013
Scope: High-Pressure Steam Piping, Welding & Support Fabrication
Project Description
In 2013, ISPC partnered with Site Technology to execute a major infrastructure project at the Chekka Cement Plant. The project involved the Combined Cycle Piping Installation for a new closed-loop power generation system. This system was designed to recover waste heat from the cement production process and convert it into electricity, increasing the plant’s energy efficiency.
Scope of Combined Cycle Piping Installation
1. High-Pressure Piping Works:
Steam Lines: Fabrication and erection of heavy-wall alloy steel piping to transport high-pressure steam from the Heat Recovery Steam Generators (HRSG) to the steam turbine.
Cooling Water Loop: Installation of large-diameter carbon steel piping for the closed-loop cooling water system.
2. Welding & Fabrication:
Certified Welding: Execution of critical TIG and Arc welding on high-pressure joints, subject to 100% Radiographic Testing (RT) to ensure zero defects under high operating temperatures.
Pipe Supports: Fabrication and installation of robust steel supports, hangers, and expansion loops to accommodate thermal expansion in the piping network.
3. Testing & Commissioning:
Hydro-Testing: Conducting hydrostatic pressure tests at 1.5x operating pressure to verify the mechanical integrity of the entire Combined Cycle Piping Installation.
Steam Blowing: Performing steam blowing operations to clean the lines of any debris before connecting them to the sensitive turbine blades.
Key Challenges & Solutions
Challenge: routing complex piping networks through an existing, congested industrial facility without disrupting daily cement production.
Solution: ISPC utilized 3D modeling and pre-fabrication of pipe spools off-site to minimize installation time and on-site welding.
Results
The piping system was delivered leak-free and on schedule. This project highlighted ISPC’s capability in handling complex Industrial Piping projects within the heavy industry sector.
