HRSG & STG Pipe Rack Modules for the SaskPower Chinook Power Station


From concept to reality

Structural Steel Fabrication & Modularization for SaskPower Chinook Power Station

In July 2017, Burns & McDonnell awarded Saskarc with a contract for the supply of four large modules. Two of these were STG modules, and two were HRSG modules. These large modules were completed for the SaskPower Chinook, Gas Fired Power Station in Swift Current, Saskatchewan.

Saskarc performed a variety of work for this project. The scope of the work included:

  • Receiving, inspection, assembly, fit-up & welding of all structural steel,
  • Installation of ladders, hand rails and pipes,
  • Touch-up painting,
  • Detail, supply, fabricate and install the small-bore piping,
  • Receiving, inspection, installation, welding and testing of all free-issued large bore chrome and carbon steel pipe,
  • Laser dimensional scanning,
  • Module weighing & centre of gravity reports,
  • Transportation to site.

Highlights:

Assembly/modularization and transportation of some of largest pipe modules ever modularized in Western Canada.

  • 2 x STG modules = 31’-6” wide x 64’ long x 26’-6” tall x 85 tonnes each.
  • 2 x HRSG Modules = 33’ wide x 116’ long x 26’ tall x145 tonnes each

The project was all performed indoors, in a controlled shop environment with large overhead cranes, to mitigate cost and schedule impact from the cold winter conditions.

Given these modules were all performed offsite, this allowed the earth works and foundations to be performed on-site at the same time and then the modules could be placed ‘plug and play’ style, significantly reducing the over-all project schedule.

Challenges:

Given most of the materials were free-issued by our client, this project required extensive coordination with the client and their vendors, to plan and schedule so the assembly schedule was aligned with when materials would arrive at our facility.

This project required extensive amounts of 3rd party pre-heat & post-weld heat treatment and non-destructive (NDE) testing. This had to be closely coordinated between all the different disciplines working on the modules, as well as the 3rd party vendor performing the work. Radio graphic testing especially had to be coordinated, as the facility had to be shut down for this process to safely take place.

Due to some of the free-issued materials being delayed, the delivery of the modules was pushed from the Winter months into the Spring road ban season. This led to challenges that had not previously been navigated. Saskarc and our transportation company had to work closely with the various government bodies (Department of Highways, Department of Bridges, SGI, multiple different RMs) to gain approval to move these massive modules.

Result

Given the size and complexity of these modules, the many disciplines involved and the free-issued material coordination, this project had many challenges, but through regular communication and teamwork between Saskarc’s team and our client’s team, this important project was a key success to the over-all project.