Survey
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
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 19