Suncoke & Gateway Energy | New Coke Plant
Mechanical subcontractor for SunCoke and Gateway Energy's $290 million coke plant serving US Steel, with 120 heat-recovery ovens and steam systems.
- Owner
- Consumers Energy
- Value
- $1,727,000
- Construction Manager
- ALSTOM Power
- Architect
- ALSTOM Power
- Industries
- Industrial
- Power
- Utility
- icon's role
- Fabrication & Modular
- Mechanical Construction
- HVAC & Sheet Metal
icon Mechanical leveraged extensive pre-job planning and shop fabrication to deliver the Karn Unit 1 Gland Steam/Turbine Retrofit with the highest quality and customer satisfaction. By shifting fabrication off the critical path of the outage—most notably pre-building the new gland steam valve station on a shipping frame—icon reduced field labor, controlled cost, and protected the owner's schedule during a time-critical turbine outage.
Scope of Work
- Pre-outage installation of gland steam pipe fabrication in tight areas around the low-pressure turbine condensers.
- Selective demolition of antiquated gland steam system.
- Pre-fabrication of new gland steam valve station consisting of approximately 160 welds for high pressure steam. The station was fabricated on a shipping frame, so the installation was completed with 6 tie-in welds reducing cost for the owner and valuable time during the outage.
- Installation of a new gland steam condenser.
- Installation of new access ways in the existing condensers walls for access to LP extraction lines and gland steam supply and return pipe work.
- Installation of new stainless steel hood spray piping on the LPs.
- Removal and replacement of 16” extraction bellows in the LP condensers.
- Installation of welded spools on LP extraction lines for reconnection of the lower turbine casings to existing plant piping.
- Modifications to existing 2” thick turbine gland steam pedestals for installation of new gland steam supply and return piping.
Project Insights
- ~160-weld valve station prefabbed on a shipping frame → 6 field tie-in welds
- Built to ASME B31.1 with complete weld mapping + NDE
- 100% 16 ga. stainless cladding on condenser piping
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