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16
Highlights – April 2012
Djebel Ressas:
Installation begins
In a southern suburb of Tunis, the capital of Tunisia,
work continues on the new state-of-the-art cement
plant for Carthage Cement: Djebel Ressas. In June
2011, just over a year after the contract with FLSmidth
became effective, Stage 2 began.
The October 2011 issue of Highlights covered Stage 1 of the Djebel Ressas project.
Carthage Cement contracted FLSmidth to
help develop the largest and most technologically advanced cement plant in North
Africa. When finished it is expected to
have a production capacity of two million
tons of clinker each year.
An international team has come together for
this large undertaking. FLSmidth’s expertise
PART 2
in engineering and equipment supply com­bined with the Turkish contractor EKON’s
expertise in installation and construction is
ensuring that the end result will be a successful, high-performing plant.
Keeping track and making progress
Almost 500,000 cubic metres of soil has
been excavated and moved and steel structure and concrete are ready to support the
many tons of equipment needed to create
this advanced cement plant. Arriving by sea,
equipment has been delivered safely and
securely to Tunisia from around the globe,
thanks to the meticulous work of FLSmidth’s
shipping teams. Now the many different
parts of the site are ready to be assembled.
The equipment is stored in a 42,000 m2
storage area, and tight control of the stock
is crucial. As well as the huge pieces, such
as the gears and mills, there are also many
CONTACT Sandra Pihl Heise
[email protected]
Highlights – April 2012
thousands of pieces that only weigh a few
grams or kilos – and everything must be
kept track of; every part will be needed
before the plant installation is completed.
Big numbers
13,500 TONS OF MECHANICAL
EQUIPMENT AND 7500 TONS
OF STRUCTURAL STEEL ARE
BEING INSTALLED
FLSmidth design drawings
Some of the large pieces of equipment
are being assembled on site and this
means that the FLSmidth design drawings
are studied carefully every day to make
sure everything is assembled and installed
according to FLSmidth specifications.
Nine tower cranes are working to lift and
assemble the machines.
Supervisor at EKON, FLSmidth’s partner in
this project.
Balancing huge equipment
and fine alignment
Precision is key in plant construction and
supervisors from EKON are on site to make
sure the installation goes as scheduled.
There is little room for error as the engineers
are often working with tolerances of less
than 1mm. For example, the kiln supports
are aligned within + /– 0.2 mm.
“Installing the kiln involves the very precise
alignment of a really large, heavy machine.
One kiln roller weighs 30 tons plus an
additional 350 tons from load when in
operation. During installation, the inclination of the kiln roller is adjusted with a
tolerance of between 0 and 0.2%. This
will ensure the smooth operation and long
lifetime of the mechanical parts.”
“The balance between the huge equipment
and the really fine alignment that is necessary
is what makes plant installation exciting,”
explains Kent Almar, Chief Mechanical
Cable control
The mechanical construction is a large,
time-consuming job. But once this is done,
the installation process is still only half
complete. All the machines need to be
connected to electricity, both to distribute
power to the entire plant and also for the
communication cables, so that all the
equipment can be centrally controlled from
the control room. Approximately 800 kilometres of electrical cable need to be pulled
through underground corridors. FLSmidth
have supplied precise plans detailing which
cable must be used for each machine and
exactly where each cable must be placed.
There is a place designated for every individual cable in the FLSmidth design.
Inspection and testing
It is not only the large machines that are
inspected and controlled - the small machines,
conveyors and filters are also inspected by
the supervisors and the assembly must be
signed off.
At FLSmidth, as part of the Final Acceptance
Test, all the control and communication
systems are being assembled and the connections tested. Process and engineering
experts from FLSmidth work together with
the customer to make very sure that any
errors or shortcomings are corrected before
the whole system is packed and sent to
the site.
Time frame
It is expected that the first flame in the kiln
will be lit early 2013, and everything is on
track to meet this target. Preassembly for
mechanical installation started in June 2011
and is now around 15% complete. The
installation of concrete works is approximately 80% complete and the installation
of steel structure is 35% completed.
Teamwork
Stage 2 is well underway at Djebel Ressas.
Together with Carthage Cement, FLSmidth
is working with EKON, who manage the
on-site fabrication and installation of this
enormous plant. The mechanical, electrical
and control and instrumentation works are
being installed and tested. Once this phase
is complete, Stage 3 of the project will begin:
Commissioning, which will be covered in
the next article in this series. >>
Scan here for
video on
Djebel Ressas'
developments
SCAN HERE FOR
PART 1 ARTICLE ON
DJEBAL RESSAS’
PROJECT
17
18
Highlights – April 2012
ENGINEERING
All systems are
inspected and tested
by the customer
together with
FLSmidth inspectors
GENERAL
ARRANGEMENT
Basic
Main
Detailed
INSPECTION & TESTING
FLSMIDTH® PROJECT
MANAGEMENT
________________
Shipment
Kick off meeting
PROJECT STAGES
CONTRACT
EFFECTIVE
MAY 2010
STAGE 1
STAGE 2
Stage 2 is well underway at Djebel Ressas.
Based on FLSmidth® engineering, a team of experts
is managing the on-site fabrication and installation
of this enormous plant and the mechanical,
electrical and control and instrumentation
works are being installed.
Pre-assembly for mechanical
installation started in June
2011 and is now around
STEEL STRUCTURE
Equipment is stored in a
42,000 m storage
15% complete.
2
CASTING
area, and tight control of
the stock is crucial.
REINFORCEMENT
FORM WORK
PRE-ASSEMBLY
EXCAVATION
LEVELLING
CIVIL WORK
EQUIPMENT STORAGE
INSTALLATION
Highlights – April 2012
STAGE 3
COMMISSIONING
800
Of the 1,217 people on site,
During installation, the
inclination of the kiln
roller is adjusted with
a tolerance of between
Approximately
kilometres of electrical cable
will be pulled through
underground corridors.
528
are involved in
mechanical installation.
0 and 0.2%.
ELECTRICAL INSTALLATION
MECHANICAL INSTALLATION
ALIGNMENT
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