Of Energetic Chimneys In Egypt RECONSTRUCTION

Transcription

1 RECONSTRUCTION Of Energetic Chimneys In Egypt

2 COMPANY ACTIVITIES AT EGYPTIAN MARKET COMPANY PROFILE: Omega Teplotechna Praha a. s. is a private joint stock company of 25 years experience in branch of tall industrial chimneys. The company was established by experts in branch of designing, constructions, repairs and maintenance of tall industrial chimneys. Our company cooperates with research institutes and universities in Czech Republic as well as abroad. Such cooperation results in application of latest progressive findings in the related branch. Company Omega Teplotechna Praha a. s. is an active member of prestigious international association of owners, constructors, operators and designers of free standing chimneys CICIND ( Company is a holder of the ISO 9001:2009, 14001:2005, 18001:2008 Certificates. COMPANY S DOMAIN: Omega Teplotechna Praha a. s. realizes majority of its projects at territory of Czech Republic, nevertheless since it was founded the company attends to preparations and realizations of projects abroad, too. Currently mainly because of development and modernization of industrial branches and energetics especially in non European localities the share of projects realized abroad increases continually. FIRST PROJECTS AT EGYPTIAN MARKET: The Arab Republic of Egypt became a region which represents coming of our company onto non European markets in the best way. It is evident that in Egypt because of industrial development and increasing demand of living standard the demand for electric energy is higher and higher. This demand brings inevitably a need for building of new Power stations as well as modernization of existing Power stations. This process is conditioned by participation of companies with long term experience in field of designing, constructions, inspections and repairs of tall industrial chimneys. The first project realized by company Omega Teplotechna Praha a.s. in Egypt was the supervision of erection of the brick liners of chimneys in Sidi Krir Power station. This project was realized in Next episodes of the company at Egyptian market were the following two projects realized for companies KEPCO and ORASCOM in 2009: Supervision of bricklaying of chimney liner at El-Tebbin Power station in Cairo. Erection of brick liner of chimney in Cairo West Power station including management and supervision.

3 SYSTEMATIC ACTIVITIES AT EGYPTIAN MARKET: The projects realized by company Omega Teplotechna Praha a. s. in Egypt in 2009 confirmed the Egyptian energetic market situation and its expected development. Based on this situation, our company realized 2 following important steps: Establishing the Omega Teplotechna Praha a.s. representative at Egyptian market. Putting of regular chimney inspections into routine practice. This practice enables to determine the real technical condition of related chimneys and to prevent the constructional, technical and economical problems. Based on the results of these inspections the effective chimney repairs are always proposed. Thanks to the above mentioned steps the regular realization of repairs of Energetic chimneys at Egyptian market have been started. Since then the following projects were realized: Reconstruction of chimneys U2 and U3 of heights 121m at Shoubra El-Kheima Power Plant in Cairo: Based on the realized inspections, diagnosis and determination of actual chimneys conditions including the proposals of related repairs company Omega Teplotechna Praha a. s. was asked by the Client CEPC for reconstructions of these chimneys. The subject of these reconstructions was demolition and new walling of top 33 meters of independent brick liner based on new design, repair of reinforced concrete windshields, conductor systems, electro installations and all steel appurtenances. The reconstructions were realized in the year Reconstruction of chimney U1 of height 121m at Assiut Power Plant: The successful realization of repairs in Shoubra El-Kheima Power Plant accelerated the attention of other Egyptian Power Plants operators. As the result there was a demand for inspection and following repair of chimney U1 in Assiut Power Plant, a Power Plant operated by UEEPC. The reconstruction consisted of demolition and new walling of top 80 m of attached brick liner, repairs and coatings of reinforced concrete windshield, repairs of conductor system, electro installation and all steel appurtenances. The reconstruction was realized in the year Reconstruction of chimneys U4 and U1 of heights 121m at Shoubra El-Kheima Power Plant in Cairo: The satisfaction with the repairs realized on chimneys U2 and U3 in 2014 caused that CEPC asked Omega Teplotechna Praha a. s. also for realization of repairs of chimneys U4 and U1. The scope of reconstructions was nearly the same as in case of chimneys U2 and U3 but in this case it was necessary to demolish and wall again top 60 meters of both chimney liners. The larger extent of demolished liners was caused by continually growing degradation and quantity of cracks in original brick liners. These reconstructions were realized in the years 2015 and ACTUAL SITUATION AND EXPECTED PROJECTS AT EGYPTIAN MARKET: The activities of company Omega Teplotechna Praha a. s. at Egyptian market continue. The company prepares the designs of new Power Plant chimneys, realizes the inspections and diagnostics of existing chimneys. The results of these inspections are described in the detailed Inspection Reports, which include the proposals of effective and economical repairs of related chimneys. This procedure is the good base for continuation of successful cooperation of company Omega Teplotechna Praha a. s. with Egyptian partners operators of thermal Power Plants at Egyptian territory.

4 MONOLITHIC CHIMNEY 120 m RECONSTRUCTION in Al Walidia Power Plant, Assiut, Egypt 2014 Within the regular inspection during shutdown period of Unit 1 at Al Walidia Power Plant, Assiut 4 x 200m in 2014 was found the probable fundamental deterioration of inner brick liner technical condition of related RC chimney 120 m high. As the potential collapse of chimney inner brick liner would caused the immediate putting of Unit 1 aside, it was decided to realize the detailed technical inspection to reach the bases for the final owner s decision concerning the following steps for solving this situation. The owner ordered this research at branch expert company Omega Teplotechna Praha a.s., as this company has good references in Egypt. The actual reference project was the successful reconstruction of chimneys Unit 2 and Unit 3 at Shoubra El Kheima Power Plant in Cairo, realized in The technical inspection of chimney Unit 1 at Al Walidia Power Plant Assiut was realized in October The conclusions of this inspection were following: 1. The mortar of inner brick liner is degraded in wide scope. 2. There were found lot of vertical and horizontal cracks of brick liner wall. 3. The construction of flue duct opening is at very bad condition. Omega Teplotechna Praha a.s. elaborated the concluding Technical Report of realized chimney inspection. This Report was passed to investor on Simultaneously with this Report the Proposal of related reconstruction was elaborated. The proposal had accepted the demand of involving the local suppliers. Also the asked term of chimney operability of the Unit after its repair had been taken in consideration at this Proposal.

5 2015 In February 2015 Omega Teplotechna Praha a.s. obtained the official order from Upper Egypt Electricity Production Company (UEEPC) in which the official date of Unit operability after renovation was presented as May 2015 the more detailed determination was in relation to actual time schedule of boiler reconstruction. Omega Teplotechna Praha a.s. immediately started to prepare expedition of technologies, materials and personnel from Europe and signed the contract of bricks supply with local Egyptian producer. Reconstruction of Chimney in Al Walidia Power Plant, Assiut was realized in period of 82 days

6 March 2015 Al Walidia Power Plant, Assiut, Egypt PREPARATION OF RECONSTRUCTION, ASSEMBLY OF TECHNOLOGICAL FACILITIES The first group of our labourers arrived to Assiut at the beginning of March and started to prepare the site in Power Plant. The containers with basic materials and technologies were delivered to site on , the first part of bricks was delivered on The actual time schedule of the repair elaborated with the actual situation on site mentioned the possible start of chimney operability after repair on This date had been also in relation to the phase of the other Unit sections reconstruction. As to reach this term it was necessary to provide 2 shifts, work 24 hours a day and to solve all the unexpected problems very operatively.

7 PART DEMOLITION OF OLD LINER SECTIONS AND REPAIR OF BOTTOM SECTIONS VAULT BRICKLAYING AT SECTION WITH NEW CERAMIC LINER

8 Al Walidia Power Plant, Assiut, Egypt BRICKLAYING OF NEW CHIMNEY LINER Total reconstruction of the liner up to chimney operability in 58 days.

9 WATER BLASTING, SANITATION AND APPLICATION OF PROTECTING COATING

10 SHOUBRA EL-KHEIMA Introduction At the end of 2013 Omega Teplotechna Praha a.s. obtained a contract through their representative for the Egypt and Middle East Area for the inspection of four identical concrete chimneys at the Shoubra El-Kheima Power Station in Cairo. These chimneys, 120 m high, with a ceramic brick liner without dilatation were ca. 30 years old at the time of the inspection and no major repairs had been carried out throughout that period. The power station is operated by the Cairo Electricity Production Company which is controlled by the Ministry of Electricity and Energy of the Arab Republic of Egypt.

11 The on-site part of the inspection took place in December 2013 and was led by Czech experts with many years experience of inspecting tall chimneys. The inspection itself was rather challenging as it turned out the chimneys were in a very bad condition, two of them in serious disrepair. All the chimneys had problems with the upper part of the brick liner. This had almost crumbled away at the top edge of the windshield and loose bricks were falling down into the ceramic bricks liner and the interstice between the liner and the concrete windshield. As a result of the decay the rustproof cover of the liner started to deform and partly collapse. In the case of two of the chimneys the inspection of the inner liner was considered dangerous so that the inspection was not carried out. As regards the inspected liners, in all the cases we found 2 huge vertical cracks going through the gaps between the bricks and also the bricks themselves. The client was informed during the inspection of the possibility that the chimneys could collapse very soon. In addition to the defects mentioned above some other problems were found in the case of all the chimneys which do not affect their operation. These are as follows: small defects of windshields, faults of wiring and lightning rod systems, defects in the steel structure and leaking flue ducting inlets. After the analysis and laboratory testing all the abovementioned defects were detailed in the inspection reports and sent to the client within a month of completing the inspection. Apart from the reports for the Cairo Electricity Production Company the Omega Teplotechna Praha a.s. worked out specific recommendations for the chimney repair which were then expanded with further details by request. The suggested solution was to demolish the upper 33m of the ceramic brick liner and to substitute the demolished area by 2 independent dilatation devices on steel corbels fixed into the inner wall of the windshield. We suggested repairing the rest of the defects, including replacing the top cover of the liner. It took less than two months to prepare the project for the repair and to put together the manpower, the material and the logistics needed. After the Letter of Intent dated February 2014 and the order dated , the expert team of Omega Teplotechna Praha a.s. left for the Shoubra El-Kheima power station in April 2014 to undertake the repair of both damaged chimneys according to the phased plan, with some overlaps. According to the order schedule, the full duration of the complete repair was set to be forty-two days of downtime, and at the most three months, per chimney. The client s additional requirement was to be able to put both chimneys back into operation by the end of June Less than two months after the inspection it became clear the prognosis made during the inspection was correct. The upper part of the lining above the top edge of the windshield of one of the chimneys foundered and the cover of the liner touched the area. The chimney partly collapsed to the bottom of the liner and had to be closed. Similar indications of a collapse also started to appear on another chimney. These events were followed by the decision of the Cairo Electricity Production Company to have the two abovementioned chimneys repaired according to the suggestion of Omega Teplotechna Praha a.s. who were asked to carry out the repair.

12 SHOUBRA EL-KHEIMA Diagnostics and Technical Preparation DIAGNOSTICS Based on inquiry by the investor the company Omega Teplotechna Praha a. s. presented an offer and subsequently executed constructional technological inspection and diagnosis of four reinforced concrete chimneys in the Shoubra El-Kheima Power Plant, Cairo, Egypt. Besides the visual inspection of the chimneys, the diagnostics included also acoustic tracking and nondestructive tests for determination of surface strength of concrete, depth of reinforcement placing and depth of carbonatation at the outer surface of chimney windshield. Resulting inspection reports included: detailed description of discovered defects with photo documentation (photo and video), map of defects, commented results of non-destructive tests of concrete strength, evaluation of the condition of chimneys and proposal of measures to ensure safety and long term lifetime of the chimneys.

13 TECHNICAL PREPARATION Based on Letter of Intent from February 2014 Omega Teplotechna Praha a. s. commenced necessary technical, production and logistic works for handling of repair of 4 chimneys of the Shoubra El-Kheima Power Plant. After the results of the inspections performed in the end of year 2013 the scope of repair works of the chimneys was proposed, and after approval by the Investor the project documentation of the repairs was elaborated, which was supported by technological calculation of tensile conditions in the chimney, and by static expertise of the chimney. Together with the Design also detailed Method of Statement for the chimney repairs was elaborated, which was limited by set time schedule. The proposed technological process was directly influencing also the provision of required technology for the chimney repairs (cable transportation, working decks, etc.). Crucial for logistics due to very close date of start was to ensure not only the manufacturing of the shaped bricks of acid-resistant fireclay with long manufactory time, but also ensuring of the transportation of all materials and technology to the site in advance to not endanger the agreed milestone dates of the chimney repairs. Condition of wall and steel elements of the windshield in the part under upper platform Ventilated gap between chimney liner and windshield in the view from top

14 SHOUBRA EL-KHEIMA Assembly of Technological Facilities and Dismantling of Defected Parts ASSEMBLY OF TECHNOLOGICAL FACILITIES

15 Based on effectual contract from it was decided to start the realization swiftly in accordance with the prepared reconstruction plan. For the reason of very fast realization it was not possible to proceed with common commercial practice, such as guarantees from both sides and ensuring of realization financing. PERFORMANCE OF THE PREPARATION WORKS FOR TECHNOLOGY The groundwork was mutual trust between the Investor Cairo Electricity Production Company, commercial representative of Omega Teplotechna Praha a.s. in Egypt and Middle East Mr. Salah Abou Laban, and the Contractor company Omega Teplotechna Praha a.s. Dispatch of the first containers on EXECUTION OF THE DEMOLITION AND DISMANTLING OF DEFECTED SECTIONS

16 SHOUBRA EL-KHEIMA Realization Reconstruction of Internal Liner REFURBISHING OF OUTER WINDSHIELD SURFACE AND INNER LINER ASSEMBLY OF GRATES RECONSTRUCTION OF THE OLD INNER LINER

17 INSTALLATION OF THE NEW INNER LINER COMPENSATORS INSTALLATION INSTALLATION OF A NEW CHIMNEY HEAD

18 PROJECTS REALIZED BY OMEGA TEPLOTECHNA PRAHA A.S. IN EGYPT YEAR PROJECT LOCATION 2009 Project documentation of 2 reinforced concrete chimneys with brick liners Supervision + realization of chimney brick liner construction Supervision of chimney brick liner construction 2013 Inspections of 4 reinforced concrete chimneys with brick liners 2014 Project documentation of 2 reinforced concrete chimneys with brick liners General repair of 2 reinforced concrete chimneys with brick liners (Units 2 + 3) Inspection of reinforced concrete chimney with brick liner 2015 Project documentation of 3 reinforced concrete chimneys with brick liners Inspections of 2 reinforced concrete chimneys with brick liners (Units 1 + 4) General repair of reinforced concrete chimney with brick liner (Unit 1) Inspection of 2 reinforced concrete chimneys with brick liners (Units 5 + 6) Inspection of 1 reinforced concrete chimney with brick liner (Unit 2) 2016 General repair of 2 reinforced concrete chimneys with brick liners (Unit 4+1) Inspection of reinforced concrete chimney with brick liner (Unit 1) Inspection of reinforced concrete chimney with brick liner (Unit 2) Cairo West Power Plant Cairo West Power Plant El-Tebbin Power Plant, Cairo Shoubra El-Kheima Power Plant Suez Power Plant Shoubra El-Kheima Power Plant Assiut Power Plant South Helwan Power Plant, Cairo Assiut Power Plant Shoubra El-Kheima Power Plant Cairo West Power Plant El Kuraimat Power Plant Shoubra El-Kheima Power Plant El Kuraimat Power Plant Assiut Power Plant Contact Persons: Ing. Bohumil Ježek, CEO Chairman of Board Ing. Vít Černý, International Business Manager, cerny@ot.cz Velehradská Praha 3 tel: fax: omegatep@ot.cz Czech Republic Our Representative in Egypt & The Middle East: Salah Abou Laban Tel: salahaboulaban45@gmail.com