Edwardsport, Indiana

Air Separation Unit Installation at New IGCC Facility

Client / Owner

Duke Energy (Air Products and Chemicals, Inc.)

Architect / Engineer

Air Products and Chemicals, Inc.




Graycor Industrial

Project Scope

As part of Duke Energy’s new Integrated Gasification Combined-Cycle Facility, Graycor performed a complete above-ground, two-train air separation unit installation. Project scope included erection of 26,500 linear feet of piping (approximately 6,000 linear feet of oxygen clean piping), including piping pneumatic pressure testing up to 1,300 psi. Graycor’s team performed nearly a dozen critical/heavy lifts including development of lift plans and installation of crane pads necessary for setting:

Two 4-core heat exchanger boxes (327,800 lbs.)
Two HP/LP columns (292,000 lbs.)
Two 2-core heat exchanger boxes (210,000 lbs.)
Two MP columns (169,280 lbs.)
Three liquid oxygen storage vessels (155,300 lbs.)
Graycor’s team also set and installed 163 pieces of equipment, including (13) 15,000-HP compressors, and erected 500 tons of structural steel including:

Two 210’ x 50’ x 60’ pre-engineered buildings with crane bays (including installation of catwalk systems, crane rails, roof fans, and louvers)
Two TSA access platforms/pipe support steel
Miscellaneous stands/supports structures/access platforms
In addition, we provided support services for Air Products and four Air Products subcontractors including:

Complete electrical, insulation and painting
Material handling
Equipment setting
Piping pressure testing