CP-84 Ore to Picadilly in Sussex, N.B.
Completed: January 2013
Lorneville was contracted to install piping and equipment within the existing PCS Penobsquis Potash Wet Mill. The new infrastructure allows ore to be pumped to the new Picadilly mine for commissioning, while tailings from the new mine are pumped to the existing mine and stored underground. As part of this project, Lorneville installed stainless steel, carbon steel rubber lined, fiberglass reinforced, and high-density polyethylene fusion welded piping. Large tanks, pumps, cyclones, and specialized equipment were also installed under this contract.
Alstom Fundy Tidal Power Project Turbine Augmenter
In conjunction with a government sponsored initiative, Alstom Hydro is undertaking to install a 1 MW unit on the ocean floor in the Bay of Fundy designed to generate electricity from Tidal Currents. FORCE, a government sponsored organization is responsible for laying the connection cables. Alstom is responsible for the design, construction, and installation of the unit. Lorneville has completed the fabrication of the Augmenter. It houses the generator and is approximately 45ft in diameter x 22ft wide x 156 Tonnes.
Picadilly Mine Air Building
Completed: December 2012
In 2012, Lorneville was contracted through Cementation at the PCS Picadilly Mine expansion in Sussex, New Brunswick to fabricate and install process piping in the new mine air building. The project included the installation of stainless steel chilled water piping, placing pumps and equipment, installing cooling coils, and the construction of a large cooling tower. As part of the scope, Lorneville also installed the natural gas and propane piping.
JDI Lake Utopia Biomass Boiler Construction
Completed: March 2011
Lorneville was the primary mechanical contractor for the construction of a Wellons 4-Cell 110/140,000 PPH Wood-Fired Boiler System with electrostatic precipitator. Upon completion of civil foundation work, mechanical construction occurred over a period of approximately six months. This included the construction of the boiler building, fuel delivery system, boiler, and electrostatic precipitator. The Biomass boiler was installed to provide plant steam to the adjacent corrugated medium mill.
Waste Spent Acid Condenser Design, Fabrication, and Installation
Completed: Fall 2011
The waste spent acid condenser project for Irving Oil in Saint John, New Brunswick involved the fabrication and Installation of the Haldor Topsoe WSA Condenser as well as all of its associated Ductwork. Lorneville’s timeline for this project was very aggressive due to the rapidly deteriorating condition of the existing unit and the urgent need for its replacement.
Despite numerous challenges associated with technical nature of the project and timelines, Lorneville’s work was a success on all fronts: safety, quality, schedule, and budget.
Supply and Installation of Stainless Steel Filtrate Tank
Completed: March 2011
As part of a long-range plan to increase production at their Pulp Mill, Irving Pulp & Paper planned to remove the existing filtrate tank from their Saint John, New Brunswick facility and upgrade to a larger tank. As part of this project, Lorneville was contracted to complete the detail design of the tank to API650 Standard, as well as for transportation and lifting fixtures. To complete this project, the tank was fabricated in four sections and fully fitted in shop prior to shipping to site. The tank was then shipped in four pieces—two tank halves and two half roof sections. Once each section arrived on-site, field installation was completed by Lorneville personnel.
Rougher Floatation Banks PCS Picadilly Project
Completed: Fall 2010
The Rougher Floatation Banks were built by Lorneville in Saint John in 2010. There was a total of four floatation banks supplied with five mixing bays each. The tanks were 316L stainless steel construction with ¼” FRP Launders. The design criteria was:
- Indoor, Maximum Height of Slurry (From Base) of 78.25”
- Content S.G. of 1.5, Flow Rate = 15,150 Cu. Ft./Hr (429 Cu. Meters/Hr)
- Operating Internal Air Pressure of 6.0 PSI (42 KPA)
The Floatation Banks had to be continuously supported beneath both sides of the vertical wall section.
Irving Oil Commercial Tank Farm Refurbishment
The scope performed by Lorneville on this project included the replacement of 37,000ft of existing piping, consisting of fuel and fire suppression foam lines. Utilizing a directional drilling/weld and pull installation strategy, Lorneville installed 6,000ft of underground lines which run parallel to HWY 111, and cross under a heavily used four-lane public road that was left open during work.
Lorneville performed ahead of schedule with a final overall install rate of 1.6 direct hours per foot. Over 100 welds were x-rayed on the project, with only one portion of one weld having to be repaired, for a repair rate of 1%.
Emera Energy Bayside Generating Station Turbine C-Inspection
Lorneville has executed numerous maintenance projects for the Bayside Generating Station, owned by Emera Energy. Bayside Power is located in Saint John, New Brunswick and is considered the most thermally efficient unit in the Maritime region.
Lorneville’s major maintenance activities include tear down, removal, inspection and repair services to the gas turbine and HRSG, and major maintenance on the station’s steam turbine.
Foster Wheeler Reformer Hydrogen Furnace Upgrade
Over a 15 day period, Lorneville completed a full upgrade of the Foster Wheeler Reformer Hydrogen Furnace at the Irving Oil Refinery. The scope of this project involved the replacement of:
- The reboiler
- The catalyst tube inlet headers
- All catalyst tube inlet and outlet pigtails
- All the catalyst tubes
- Two rows of convection tubes
In total, there were 184 tubes, 368 pigtails, two outlet, and two Inlet headers replaced.
This upgrade involved the welding of unassigned metals to a high alloy pigtail (35% nickel, 25% chrome). During the course of preparation, Lorneville developed extensive work techniques and training for welders—including the development of specialized purging procedures, welding techniques, and specialized welding equipment. Because of this preparation, only two weld repairs were required out of a total of 700 completed and tested welds.
Coleson Cove 900 MW Thermal Plant Upgrade Project
Lorneville was hired by NB Power to design, fabricate, and install a new Flue Gas Breaching System as part of the Coleson Cove 900 MW Thermal Plant Upgrade Project. During this project, we used fabricated modules to gain efficiencies in field construction activities. With the efficiency knowledge we gained, large modules were fabricated in our shop, including:
- Six units, 150ft long x 21ft in diameter x 140 Tonnes
- Eight units, 110ft long x 21ft in diameter x 110 Tonnes
- Twelve units, 60ft long x 21ft in diameter x 40 Tonnes
Once complete, these modules were shipped to the thermal plant in Coleson Cove for installation. Lorneville applied a unique approach to rigging for this project, which allowed us to position large components beyond the reach of cranes. This method was a critical factor in the success of this project.
Superpot Installation at CNRL
Lorneville conducted full site construction, supervision, HSE, and QA services for the installation of a superpot at the CNRL Horizon Site near Fort McKay, Alberta. The Superpot vessel was manufactured by Saskarc Industries, and was delivered to site in four sections, weighing up to 270,000 lbs.
This project consisted of approximately 50,000 man-hours, and Lorneville’s scope included:
- Installation of support frame steel
- Offloading superpot sections and lifting into place
- All site structural welding
- Installing and welding of CCO wear plates on-site
Spring Turnaround at Nanticoke Imperial Oil Refinery
Lorneville executed a Spring Turnaround at the Imperial Oil Refinery in Nanticoke, Ontario. Lorneville’s scope called for approximately 25,000 hours and involved the following work:
- Opening and closing of vessel and tray manways
- Replacement of trays
- Replacement of monel nozzles
- Replacement of demister pads
- Weld repairs and overlays on shell and nozzles
The complete work scope was executed without any first aids or injuries and Lorneville was recognized by IOL Turnaround Management as having been the best contractor in applying the IOL LPS (Loss Prevention System) during this project.
Canaport LNG Mechanical Equipment and Pipe Installation
Completed: Fall 2009
Lorneville was responsible for installing mechanical equipment for the Canaport LNG facility. A project highlight was the installation of the four main unloading arms, which are among the largest in the world. These marine unloading arms are designed to accommodate the extreme tides of the Bay of Fundy, and the size of the arms, along with the configuration of the jetty, made this job complex. Lorneville successfully executed this project through the utilization of safe work practices and thorough technical planning.
In addition to installing the unloading arms, Lorneville’s scope of work included the installation of the submerged liquid natural gas pumps, emergency generators, and the fire suppression system. Lorneville was also responsible for the fabrication and installation of 3,100ft of 30” pipe from the existing facility to the Canaport LNG Jetty Head.