Embed Size (px)
Citation preview
PROJECT REFERENCE LIST
Client: ESKOM
Service: Manufacturing
Executive summary: Fabrication of steam distribution ducts and
exhausting ducts for the Medupi power station.
Dimensions and material: Ducts fabricated from carbon steel,
various size ranging from a 900 mm to 6000 mm OD, which make
up a total of 470 tons of ducts manufactured.
Year of fabrication: 2010
Key highlights: Over 100 ducts successfully delivered to client.
GUNK STABILISERSGUNK STABILISERSGUNK STABILISERSGUNK STABILISERS
Client: Sasol
Service: Manufacturing
Executive summary: 2 Multi Chamber Gunk Stabilisers fabricated
from stainless steel (304L) with a design and operating pressure
of 2610 kPa and 415 kPa respectively. ASME VIII Div 1 was the
governing code for design & construction.
Dimensions: 1200mm ID with a total length of 11650 mm. A
material thickness of 10mm/18mm with a total weight of 15 490
kg.
Year of fabrication: 2014
Key highlights: Unique dual vessel design incorporating
specialised custom forgings and unique weld design.
MEDUPI DUCTINGMEDUPI DUCTINGMEDUPI DUCTINGMEDUPI DUCTING Client: SASOL
Service: Manufacturing
Executive summary: Plant Water Pulsation Dampener manufactured
form SA516 Gr. 60 carbon steel for the sole purpose of severe cyclic
service. Design and operational temperature of 200°C and 109°C
respectively. Full scope included heat input control, post weld heat
treatment and production test plates.
Dimensions: 850 mm OD, 2910mm in length and a nominal thickness
of 25 mm.
Year of fabrication: 2014
Key highlights: Implemented innovative solutions in solving cracking
due to severe cyclic stresses.
CTFECTFECTFECTFE
Client: Sasol
Service: Manufacturing and Assembly
Executive summary: Fabrication of 24 modules which includes Filter
Press, Tank Farm, Pipe Racks, Condensate and Evaporator buildings.
Dimensions: After installation of final product, the expected
dimensions are approximately 150m in length with a width of 50m. A
total weight of over 1500 tons.
Year of fabrication: 2015
Key highlights: First ever modular plant assembly project in the
southern hemisphere.
PULSATION DAMPENERPULSATION DAMPENERPULSATION DAMPENERPULSATION DAMPENER
Client: SASOL
Service: Maintenance and Shutdown
Executive summary: 2 Rectisols found on the Sasol Secunda Plant.
Repairs and maintenance on the Rectisol includes Gaskets, valves,
heat exchangers, drums and pressure vessels.
Pressure testing takes place once maintenance is completed.
Key highlights: 8 years of experience.
BULLETSBULLETSBULLETSBULLETS
Client: Sasol
Service: Manufacturing
Executive summary: 5 Propylene storage bullets and 1
Depropaniser Stabilisation Drum was fabricated from carbon steel
with a design pressure of 2 MPa and operating pressure of 1.815
MPa. The Bullets had an MDMT (Minimum Design Metal
Temperature) of -45°C and the Drum with a MDMT of 0°C.
Dimensions and material: 6000 mm ID with a total length of 59090
mm. A material thickness of 45mm/50mm with a total weight of
446 459 kg.
Year of fabrication: 2013
Key highlights: Single piece post weld heat treatment of all vessels
in our one-of-a-kind heat treatment furnace measuring 60m in
length. This was also the largest vessel fabrication project
manufactured by a South African company.
Key highlights: 5 Bullets manufacture at Hydra-Arc’s state of the
art facilities.
RECTISOLSRECTISOLSRECTISOLSRECTISOLS
Client: Government
Service: Manufacturing and Construction
Executive summary: Water Tanks fabricated with a design
temperature and 40°C.
Dimensions and material: Water tanks manufactured from
Ferritic-stainless steel shell (3CR12) and structural steel
supports. OD of 6.5m , total length of 22.4m and a 8mm
thickness to make up a volume of 700 000L
Year of fabrication: 2014 (Still ongoing of next orders)
Key highlights: Ongoing fabrication to supply water to remote
areas.
GASSIFIERSGASSIFIERSGASSIFIERSGASSIFIERS
Client: SASOL
Service: Shutdown and Maintenance
Executive summary: 84 Gassifiers on the Sasol Plants which
see regular successful maintenance. General Overhaul
includes Gassifier jacket replacement, pressure vessel repair
and replacement of Raw Gas Outlet Nozzles.
Mechanical maintenance is conducted on the Gassifiers. This
includes mechanical maintenance as a turnkey service.
Pressure tests are conducted once mechanical maintenance
is completed.
Key highlights: 17 years of experience in Gassifier jacket
replacement. 70 mm thick horizontal sub-arc welding
employed on sectional shell replacements. Record
completion time improvement from 21 to 7 days general
overhaul period.
WWWWAAAATTTTEEEERRRR TTTTAAAANNNNKKKKSSSS
Client: SASOL
Service: Assembly
Executive summary: New technology GHHER (GAS HEATED
HEAT EXCHANGE REFORMER) manufactured from Alloy 602CA.
Scope included final assembly welding of Alloy 602CA and P3
and P4 material.
Dimensions and material: 1250mm OD and a total length of
22000mm.
Year of fabrication: 2014
Key highlights: First of its kind with specialised welding
techniques employed.
BOILERSBOILERSBOILERSBOILERS
Client: SASOL
Service: Shutdown and Maintenance
Executive summary: 17 Boilers currently on Sasol Plant which
undergo continuous maintenance. General Overhaul incudes
structural, tube refurbishment and burner repairs. Tube
refurbishment includes convection tubes, super heating tubes
and sidewall tubes.
Material: Convection material- P1 Tubes, Super Heating Tubes-
P4 material and Boiler- P3 material
Overlay time: 55-60 days
Experience: 17 years of experience.
GHHERGHHERGHHERGHHER Client: SASOL
Service: Shutdown and Maintenance
Executive summary: Gas reformers on the Sasol plants form part
of the GHHER project. Gas reformers experience a day to day
maintenance. Tube and heat exchanger repairs done with special
welding techniques. Special welding techniques used specifically
to minimize heat treatment. Pressure testing done after
completion of maintenance activities.
During shutdown period regular maintenance and replacement
of valves.
Overhaul time: Daily maintenance
Experience: 17 years of experience.
NAFTANAFTANAFTANAFTA
(COAL PROCESSING)(COAL PROCESSING)(COAL PROCESSING)(COAL PROCESSING)
Client: SASOL
Service: Maintenance and Shutdown
Executive summary: Coal processing undergoes structural and
mechanical maintenance activities.
Key highlights: 17 years of experience.
WATERWORKSWATERWORKSWATERWORKSWATERWORKS
(Water Purifying Plant)(Water Purifying Plant)(Water Purifying Plant)(Water Purifying Plant)
Client: SASOL
Service: Maintenance and Shutdown
Executive summary: Water purifying plant experience day to day
maintenance. Maintenance overhaul includes pressure vessel
repairs and removing/replacing of the degraded areas.
Key highlights: 17 years of experience.
UNIT UNIT UNIT UNIT 21212121/221 (GAS REFORMERS)/221 (GAS REFORMERS)/221 (GAS REFORMERS)/221 (GAS REFORMERS)
Client: SASOL
Service: Maintenance and Shutdown
Executive summary: Oxygen plant experience day to day
maintenance
Material: Oxygen plant is made up of mainly aluminium and
stainless steel heat exchangers & pressure vessels.
Maintenance overhaul includes pressure vessel work,
cooling boxes maintenance and heat exchangers repairs.
Key highlights: 17 years of experience.
TAR SEPARATOR TANKSTAR SEPARATOR TANKSTAR SEPARATOR TANKSTAR SEPARATOR TANKS
Client: SASOL
Service: Manufacturing
Executive summary: 4 Enabling primary and 2 secondary tar
separator tanks was fabricated from carbon steel with a
design temperature of 175°C and an operating temperature
of 95°C. PWHT (Post Weld Heat Treatment) was conducted
due to service of stress corrosion cracking.
Dimensions: 8000mm ID/13 000mm with a total length of
12927mm. A material thickness of 10mm/13mm with a total
weight of approximately 80 000 kg per unit.
Year of fabrication: 2013/2014
Key highlights: In situ PWHT with complex internal
geometry.
OXYGEN PlantOXYGEN PlantOXYGEN PlantOXYGEN Plant
Client: SASOL
Service: Manufacturing
Executive summary: A Methanol Recovery Column was
fabricated from stainless steel (316L) with a design and
operating pressure of 450 kPa and 115 kPa respectively. Weld
deformation control was critical. ASME VIII Div 1 was the
governing code of construction.
Dimensions: 1900 mm ID with a total length of 37955 mm.
material thickness of 8 mm with a total weight of 23 012 kg.
Year of fabrication: 2014
Key highlights: Our first thin walled slender column with over
55 internal trays and external support rings delivered on an
accelerated schedule.
METHANOL RECOVERY COMETHANOL RECOVERY COMETHANOL RECOVERY COMETHANOL RECOVERY COLUMNLUMNLUMNLUMN
Client: SASOL
Service: Maintenance and refurbishments
Executive summary: Fabricated 18, 6 and 2 inch carbon steel
pipes to be operational in the Mozambique gas pipeline
system.
Dimensions and material: A total weight of 8 tons of various
lengths fabricated over a 2 week period.
Year of fabrication: 2014
Key highlights: 18 years of fabrication experience.
HEAT EXCHANGER HEAT EXCHANGER HEAT EXCHANGER HEAT EXCHANGER
RETUBINGRETUBINGRETUBINGRETUBING
Client: SASOL
Service: Maintenance and Refurbishment
Executive summary: Hydra-Arc employs state of the art
facilities that are capable of retubing and total refurbishment
of heat exchangers of various sizes.
Dimensions and material: Retubing of typical heat exchangers
with 1600 tubes and a shell OD of 1.5m will on average be
completed within 28 days.
Key highlights: 18 years of refurbishment experience within
the petrochemical environment.
MOZAMBIQUE GAS PIPEMOZAMBIQUE GAS PIPEMOZAMBIQUE GAS PIPEMOZAMBIQUE GAS PIPEINGINGINGING
Client: SASOL
Service: Maintenance and Refurbishment
Executive summary: Refurbishment includes complete machining
out of all erosion wear back to sound metal, followed by semi-
automated weld build-up to original design thickness. The vessels
are fabricated from SA-302 Gr. B steel.
Dimensions: 3.5 m OD with 70mm to 75mm thickness.
Key highlights: Hydra-Arc employs state of the art facilities that are
capable of refurbishing over 100 Ashlocks, and Coal locks on a
continuous basis. 6 Year experience on Ashlock refurbishments.
GASSIFIER AND BOILER GOGASSIFIER AND BOILER GOGASSIFIER AND BOILER GOGASSIFIER AND BOILER GO
Client: SASOL
Service: Maintenance and refurbishments
Executive summary: Maintain and fabricate parts for Gassifiers and
Boilers.
Dimensions and material: Various
Key highlights: With 5 years of maintenance experience in
Gassifiers and Boilers, and excellent facilities allow Hydra-Arc the
capability to maintain Gassifiers and Boilers that weigh over 100
ton.
ASHLOCKSASHLOCKSASHLOCKSASHLOCKS
Client: SASOL
Service: Maintenance and refurbishments
Executive summary: Refurbishment of Fin Fan Banks
Dimensions and material: No limitations on size.
Key highlights: 16 years of experience. With Hydra-Arc’s
experience level and state of the art facilities allow for
refurbishment of Fin Fan Banks over 100 tons.
PIPINGPIPINGPIPINGPIPING
Client: SASOL
Service: Manufacturing
Executive summary: Hydra-Arc employs the luxury of facilities
which allow for fabrication and design of pipes with various
dimensions.
Dimensions and material: Various shapes, sizes and materials.
Key highlights: 18 years of experience.
FIN FAN BANKSFIN FAN BANKSFIN FAN BANKSFIN FAN BANKS
Client: Various
Executive summary: Hydra-Arc facilities allow for designs and
construction of industrial and public facilities.
Dimensions and material: Various
Year of fabrication: Capability since 2010
Key highlights: Entire Sky-Hill Facility, Grand Palace, Mshiniwami
Welding School, Work Shops and various industrial and commercial
buildings.
GASSIFIER JACKETSGASSIFIER JACKETSGASSIFIER JACKETSGASSIFIER JACKETS
Client: SASOL
Executive summary: Gassifier Jackets are fabricated on Hydra-Arc
premises. Along with fabrication, Hydra-Arc also redesigns and
optimises Gassifier Jackets to increase operational life.
Dimensions and material: Various
Key highlights: 4 years of experience.
STRUCTURALSTRUCTURALSTRUCTURALSTRUCTURAL
