KC Energy – 2 off Fly Ash boiler and 1 off Extraction Exhuast Turbo Generator (EETG) electrical design and support

Client: KC Energy
Purpose: Provide electrical engineering design, installation and commissioning support
Pressure: 67 barg
Temperature: 480 oC
Flowrate: 2 X 30 T/hr
Fuel: Duff coal
Project type: Brownfields

IES provided substantial electrical engineering services into the KC ENERGY, Combined Heat and Power (CHP) installation on the KARBOCHEM site. All the Balance of Plant (BOP), electrical engineering design, drafting, specification, installation oversight and commissioning of the plant was completed. Electrical and to a certain extent, Control system interfacing with the existing KARBOCHEM grid; package suppliers and existing equipment was successfully performed.

Newcastle Newcogen – 1 MWe Reciprocating Gas Engine (RGE), Balance of Plant (BOP) design

Purpose: Provide Engineering and design services for the installation of a 1 MWe RGE
Fuel: Natural Gas (SASOL Gas)
Project type: Brownfields

NEWCASLTE NEWCOGEN required engineering support for the design and installation of the Balance of Plant (BOP) systems required for the installation and operation of a containerized 1 MWe DEUTZ engine. The project entailed the Engineering, Design, Drafting and Engineering support for the installation of the RGE. The systems included the fuel supply network from the existing piping network; electrical systems interfacing and power evacuation.

SAPPI – 10 MWe Extraction, Exhaust Turbo-Generator supply

Purpose: The supply of a 10 MWe Extraction, Exhaust Turbo-Generator
Steam pressure: 62 bar
Steam temperature: 420 oC
Mass flowrate: 110 T/hr
Fuel: N/A
Project type: Brownfields

SAPPI Tugela’s 10 MWe Extraction Exhaust Turbo-Generators (EETG) were de-commissioned after a period of extended operation. IES/TRIVENI was awarded with the supply of an EETG after a detailed tender process.

Kelvin Power – Steam ejector piping design

Purpose: Steam ejector piping routing and design
Steam pressure: 70 bar
Steam temperature: 490 oC
Mass flowrate: N/A
Fuel: PF boiler
Project type: Brownfields

KELVIN POWER had been experiencing some problems with the online steam ejectors. As part of the ejector overhaul, the ejector piping needed to be rerouted. The system was reverse engineered and a new routing specified. Improvements to the existing ejectors are currently being developed in conjunction with APPLIED VACUUM.

Kelvin Power – Boiler water chemistry monitoring system installation

Purpose: Online boiler water chemistry water analysis
Pressure: 70 bar
Temperature: 490 oC
Mass flowrate: N/A
Fuel: PF boiler
Project type: Brownfields

KELVIN POWER required online water monitoring systems installed to their existing PF coal fired boilers (6 off). The project entailed the Engineering, Design, Drafting and Engineering support for the installation of the boiler monitoring system. Design included the piping network from the nozzle tie in point to the chillers and sampling room; layout design of all equipment; cooling water piping system design and drain system design.

AEL – Standby Diesel Fired boiler installation

Purpose: Backup steam production
Pressure: 30 bar
Temperature: 300 oC
Mass flowrate: 30 T/hr
Fuel: Diesel
Project type: Brownfields

IES was commissioned to specify and source a backup boiler towards the end of 2015 to act as a backup boiler for AEL’s “Fly Ash” boiler. Due to the very short lead time requirement from the client, a Diesel fired boiler was sourced from the USA. IES provided the complete array of Engineering, Design, Drafting, Project management, Installation support and Commissioning support for all aspects of the boiler, namely: Diesel Receiving system; Diesel Supply system; Ignition gas system; Economizer system; Pressure system (all pressure piping); Combustion air system; Drains and Vents; Feedwater system; Desuperheating system; General compressed air system and Control compressed air system. The boiler was successfully installed and commissioned towards the end of 2015.

AEL – Combined Heat and Power Station pre-feasibility study 

Purpose: Pre-feasibility study
Fuel: Fly Ash
Project type: Greenfields

IES was requested by AEL to perform a “fast tracked” pre-feasibility study into replacing their existing Fly Ash boiler as their primary Process steam generator. In order to develop scenarios, fuel sources, steam raising technology, location, steam requirements, power requirements and materials handling logistics were considered. The study yielded positive results with the option of a CHP plant, it’s benefits (financial and technical), and high level technical aspects being specified.