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James Construction Group, with its diverse capabilities, performed several phases of work on the Westlake hydrogen facility, including the civil phase and the mechanical construction activities on Phases I and II. 

Civil Phase

• Demolition and abandoned pipeline removal

• Stripping, excavation, and embankment

• Installation of 660 LF of 24² PVC pipe and 100 LF of 8² HDPE firewater piping

• Placement of 5,000 tons 610 bahama stone

• Erected formwork for 19 interconnecting foundations

• Installed rebar, anchor bolts and embeds

• Placed 6,200 CY of concrete foundations

Mechanical Phase

• Erection and assembly of reformer and associated equipment

• 732 tons of refractory lined ductwork

• 284 tons of panels for radiant box

• Key components to the reformer include radiant section, convection section, steam drum, process gas boiler area, PSA area, and associated piping

• 1,858 tons of equipment to be set

• Installation of nine large process module skids

• Installation and alignment of hydrogen compressor skid and motor

• Erection of 450 tons structural steel

• Assembly and erection of elevated flare stack and associated piping

• Installation of water treatment system

• Erection and assembly of the air cooler support system and associated components which include tube bundles, plenum, fans, motors, motor mounts and belts

• Installation of the oil/water separator system

• Erection of the shell and tube heat exchanger

• Assemble and install polyethylene tanks and pumps

• Install ammonia injection system skid leveling, aligning skid, blower and motor assembly

• Erection of power distribution center and analyzer buildings

• Precommissioning

• System testing and turnover

• Installation of 28,000 LF of 1/2" to 30" process pipe

• Installation of 10,000 LF of radiant tubes

Montgomery Watson Harza (MWH) subcontracted the mechanical scope of work  on this 40 mgd water purification plant to JCG.  JCG performed piping, pump installation, and equipment installation activities, including: 

• Installation of 6549 LF of carbon steel cement lined pipe ranging from 30² to 66² and 2,646 LF of carbon steel small bore pipe ranging from 1/2² to 8²

• Installation of 328 LF of stainless steel small bore pipe and 815 LF of stainless steel large bore pipe

• Installation of 49,644 LF of PVC pipe

• Installation of 2,828 LF of ductile iron pipe

• Setting and installation of 121 pieces of equipment, including pumps, mixers, tanks, blowers and an air compressor

JCG was awarded the contract on the design build and replacement of the covection sections on three existing gas fired heaters.  The purpose of the project was to improve overall performance and efficiency.  JCG partnered with Born, Inc., who completed the design, fabrication, and shipment of the convection sections.  JCG executed the schedule to install the convection sections one unit at a time to enable the Riverside facility to maintain operations.  The work was performed under a turnaround situation and completed within six days working twelve hour shifts per unit.  Construction activities included:

• Building of heaters

• Removal of existing stacks, Econ-o-mizers, and platforms

• Removal and replacement of three existing convection sections

• Addition of three 10’ stacks

• Testing of convection sections

• Completion and turnover

The Harrison County Power Project is a 550MW combined cycle power plant with 2 GE 7FA turbines.  JCG’s scope of work included sitework,  concrete HRSG and Equipment foundations, underground electrical and underground piping.  In total, JCG installed: 

• Site Preparation and Infrastructure

• 150,000 CY Excavation

• 14,000 CY Concrete HRSG and Equipment Foundations

• 7000 LF Carbon Steel Piping

• 3000 LF HDPE Piping

• 1200 LF Price Bros. Piping

JCG was on-site throughout the expansion, performing site preparation, concrete foundations, steel erection, equipment setting, piping, and final sitework and road paving.  Work was performed throughout the utility and T-ox area, wastewater treatment plant, truck loading area, and OSBL.  In all, the scope of work included:

• Clearing, grubbing, and stripping a 15 acre site

• 3500 cy concrete road and ditch paving

• 500 tons of rebar

• 7500 cy concrete cooling tower, tank, pipe rack and equipment foundations

• 400 tons structural steel erection

• 1500 LF HDPE, ductile iron and carbon steel piping

• Equipment erection and alignment

JCG installed the concrete foundations for this 550 MW Combined Cycle power plant, including the foundations for the 2 GE 7FA Turbines.  The scope of work included fine grading, placing concrete seal slab, forming foundations, installing rebar and embeds, placing concrete foundations, and wrecking the formwork.  In all, the project utilized:

• 666 tons of rebar

• 11,000 CYs concrete

JCG constructed a 60’ x 90’ x 8’ coke structure base mat.  This mat included 352 tons of rebar with 25 tons of inbed structural steel.  The civil scope of work included:

• 14,000 CY concrete

• (6) 70’ High concrete columns

• (1) Intermediate Deck

• Concrete support beam 150’ elevation w/12” deck elevated 50’ high

• Concrete table top elevated 70’

• Concrete walls and bridge crain

• (1) Coke Pit

• Miscellaneous steel erection

Air Separation & 80 MW Cogen Plant

The major equipment included: washer towers, absorber vessels, refrigerant unit, water chiller, heater skid, DeMag air compressors, Atlas Copco nitrogen compressor, tanks, and the filter box. 

The scope of work awarded to JCG on the construction of the new polypropylene plant consisted of the site development, all phases of the civil construction, and structural steel erection for a 45 acre grassroot site.  Activities included:

• Grading, stripping, and excavation
• Placement of approximately 150,000 CY of backfill material, entrance and access roads
• Installation of approximately 3,100 concrete and  timber piles ranging in lengths 60 - 95 LF in length and sheet piles
• 25,500 LF of underground carbon steel and HDPE piping
• 12,000 CY of concrete foundations
• Five spur rail entrance and fencing
• Erection of approximately 1,500 tons structural steel
• Process equipment installation and alignment