Certainty of Outcome
We built it;
we know it best.
The original constructor of corrosion and abrasion resistant linings and structures worldwide. Specializing in the design and protection against the harshest environments in the industry since 1884.
CAPABILITIES IN THE
Our longevity and lining reliability was achieved following a careful and cautious review using experienced personnel which executed similar projects. This experience includes the technical and field experience gained through the design and construction of over 50,000 Megawatts (MW) of Wet Flue Gas Desulfurization (FGD) Units over a 35 year operational history. The vessel geometry is about 60% round versus 40% rectangular for these projects. The largest FGD Unit we constructed was nominally 1100MW, while the smallest was nominally 150MW, including an amine based FGD System for the World’s first Utility-Scale Carbon Capture project.
Due to this significant experience, STEBBINS is well placed to assist with:
• Retrofit linings for wet FGD absorbers/process tanks for reliability upgrade/life extensions
• New wet FGD/process tank construction
• Carbon Dioxide scrubbers/process tanks
• Small boiler optimized wet FGD
• Integrated stack/scrubber projects
• Carbon black/cement wet FGD absorbers
• Zero liquid discharge tank and thickeners and Waste/water treatment tanks
• Supply of process tanks, linings of sumps, and miscellaneous plant construction
Our goal is to exceed the expected long-term reliability.
A) Lining Reliability
We base our designs, material selections, and installation requirements on STEBBINS’ linings which have been proven to be successful in prior FGD installations and process industry reactor/absorber vessels. Our extensive history includes:
• Over 40 years lining materials and construction operating experience in FGD applications
• Over 80 years operating experience in Process Industries scrubber/reactor applications
• Our company’s overall 135+ year history within the industry
• Implementation of lessons learned from prior FGD applications and other process industry applications
B) Resources for Large Projects (Especially Outside North America)
Key components of STEBBINS field management include:
1) SAFETY MANAGEMENT PLAN:
Our Safety Program has resulted in STEBBINS consistently exceeding our clients’ expectations. We have measured and achieved this goal on numerous large projects for some of the World’s largest companies. We believe you will find that STEBBINS has unparalleled capabilities in working safely with large crews, throughout the world. A full-time dedicated Safety Officer is onsite during execution, in addition to our other full-time Foremen and Supervisors; all trained in the highest standards of safety awareness, and regulations.
2) AVAILABILITY OF EXPERIENCED FIELD RESOURCES:
Foremen and Supervisors are permanent STEBBINS’ employees who provide training and ongoing oversight of our field crew, local installation contractors, and locally hired workers with respect to all aspects of field execution. STEBBINS selects our field crew craft very carefully, to ensure they supplement the overall project team.
3) QUALITY ASSURANCE WITH EXPERIENCED CREWS:
STEBBINS will assign crew members with prior FGD absorber project experience to act as Foremen and Supervisors on a project. They will be supported by our skilled installation field crew, local hired skilled/unskilled workers, and selected subcontractors. This approach ensures that the construction is installed using our proven installation methods under our Safety and QA/QC standards. Since the performance of the vessel is strongly dependent on the degree of quality attained during the installation, STEBBINS places high value on the installation phase by providing experienced key personnel, regardless of project location.
4) AVAILABILITY OF MATERIALS:
STEBBINS carefully selects materials through its empirical data and design process for projects. Both its manufactured and third party supplied materials are kept in inventory levels throughout our world-wide warehouses to meet our customers’ needs throughout the world.
C) Experience with Large Projects
STEBBINS’ installation experience with large projects, many in remote regions of the world, is an important consideration when evaluating our capabilities. We draw upon the same personnel that have worked in other complex projects in addition to a long list of prior wet FGD absorber installations.
D) Resource Commitment
STEBBINS commits key personnel that have demonstrated their abilities in past projects throughout various roles of project management to guarantee success.
The constructed tank concept consists of the following elements:
1. A flat reinforced slab foundation acting as the vessel floor supplied by the others. The walls will be constructed on the foundation.
2. The walls are constructed by a proven formless construction method using solid concrete block as the outside formwork and SEMPLATE as the inner formwork.
3. The mild steel reinforcement and concrete are placed between these masonry “forms” which structurally locks the anchor clinchers of the SEMPLATE into the concrete.
4. As these components rise, concrete is poured in the annular space between the “forms” using accepted concrete placement techniques, resulting in the structural wall of the tank. The wall rises each day until the last pour is made.
5. Nozzles and embedment’s are placed into the reinforcement, prior to the concrete pour and locked in place by the completed wall. Very tight tolerances can be achieved with this construction method. It also avoids leak paths associated with block outs and nozzle installation after the structural concrete wall is completed.