Post on 26-Aug-2018
Coal Handling SystemCoal Handling SystemCoal Handling SystemFire Protection Replacement ProjectFire Protection Replacement ProjectFire Protection Replacement Project
Case StudyCase StudyCase Study
SCOTT BOYLEN
GENERAL MANAGER
The The The Utility Utility Utility FPEFPE GroupGroupGroup
ED DOUBERLY
PRESIDENT
Scott
FireFire Protection System Protection System Replacement Case StudyReplacement Case Study
March 30, 2004March 30, 2004
Harrington Energy ServicesHarrington Energy Services
Harrington StationAmarillo, Texas
Tolk Station Muleshoe, Texas
Coal & Power Generation ServicesCoal & Power Generation Services
Harrington Generating StationHarrington Generating Station
Harrington Energy ServicesHarrington Energy Services
Harrington Generating Station:Harrington Generating Station:
Xcel Energy Xcel Energy –– Power GenerationPower Generation
TUCO TUCO -- Coal Service Agreement Coal Service Agreement
Savage Savage –– Coal Handling FacilityCoal Handling Facility-- Operations & Maintenance Operations & Maintenance
Services Services
Harrington Energy ServicesHarrington Energy Services
Harrington Generating Capacity:Harrington Generating Capacity:
•• 3 Units @ 350 Megawatts (1050 MWG)3 Units @ 350 Megawatts (1050 MWG)
•• Burn Rate: 12Burn Rate: 12--14,000 TPD 14,000 TPD •• Units Online: 1976, 1978, 1980Units Online: 1976, 1978, 1980•• Annual Burn: 4.5 million TonsAnnual Burn: 4.5 million Tons•• Historic PRB Plant (25+ years)Historic PRB Plant (25+ years)
Coal Flow Diagram
Harrington Energy ServicesHarrington Energy Services
•• Coal Handling Facility:Coal Handling Facility:
•• 5 5 –– 600 ton silos per unit600 ton silos per unit•• Parallel conveyor & crushing Parallel conveyor & crushing •• 18 conveyors, 14 feeders & 2 crushers18 conveyors, 14 feeders & 2 crushers•• Bottom Dump Trestle with Thaw ShedBottom Dump Trestle with Thaw Shed•• Wheel loader based operationWheel loader based operation
Lower Coal Handling SystemLower Coal Handling System
Harrington Energy ServicesHarrington Energy Services
•• Coal Handling Facility:Coal Handling Facility:
•• Savage Energy Services acquired Savage Energy Services acquired ownership & operational responsibilities ownership & operational responsibilities of the fuel handling facility November of the fuel handling facility November 20002000
Harrington Energy ServicesHarrington Energy Services
•• Asset Management & O&M Asset Management & O&M Programs initiated:Programs initiated:
•• System performanceSystem performance•• Housekeeping & Washdown systemsHousekeeping & Washdown systems•• Fire ProtectionFire Protection•• Dust CollectionDust Collection•• Spare parts inventoriesSpare parts inventories
Harrington Energy ServicesHarrington Energy Services
•• Fire Protection Project Evolution:Fire Protection Project Evolution:
•• Initial Full Scope Fire Protection Initial Full Scope Fire Protection Assessment ConductedAssessment Conducted
•• July 2001July 2001•• Formal Report accomplishedFormal Report accomplished
•• Design, Operational & Practice Design, Operational & Practice Deficiencies were identified with short Deficiencies were identified with short and long term plans being createdand long term plans being created
Harrington Energy ServicesHarrington Energy Services
ShortShort--term measures:term measures:
•• July 2001 implementation of July 2001 implementation of monthly system flushing programmonthly system flushing program
•• Fire walkFire walk--down program initiateddown program initiated•• Conducted at strategic times to Conducted at strategic times to
monitor system conditionsmonitor system conditions
JanJan--0303 FebFeb--0303 MarMar--0303
AreaArea TotalTotalSpraysSprays
PluggedPluggedSpraysSprays % % Plugged Plugged
SpraysSprays %%Plugged Plugged SpraysSprays %%
Unit 1Unit 1 5858 3535 60%60% 3636 60%60% 4141 71%71%Unit 2Unit 2 3636 1313 36%36% 1010 36%36% 33 8%8%
Unit 3Unit 3 3838 1919 50%50% 2020 50%50% 2020 53%53%
TotalTotalSpraysSprays 132132 6767 51%51% 6767 51%51% 6464 48%48%
Plugged Fire Supply PipesPlugged Fire Supply Pipes
Plugged Pipes fromExisting system
Rusted Pipe sectionfrom existing system
Harrington Energy ServicesHarrington Energy Services
•• LongLong--term measures:term measures:
•• Early Warning Fire Detection Early Warning Fire Detection SystemSystem
•• Installed September 2002Installed September 2002•• CO based monitoringCO based monitoring•• Full coal handling system coverageFull coal handling system coverage•• Proven TechnologyProven Technology
Harrington Energy ServicesHarrington Energy Services
•• Early Warning Fire Detection Early Warning Fire Detection SystemSystem
•• Air current analysis for detector head Air current analysis for detector head placementplacement
•• Network viewableNetwork viewable•• Addressable Addressable •• ExpandableExpandable
•• Multiple devicesMultiple devices•• System controlSystem control
Harrington Energy ServicesHarrington Energy Services
•• Early Warning Fire Detection Early Warning Fire Detection SystemSystem
•• Notification capabilitiesNotification capabilities•• Strobe lightsStrobe lights•• Plant pager systemPlant pager system•• Handheld radiosHandheld radios
Conspec ControlsMain PC station
CO Sensor Installedat Unit #1 Tripper Deck
Unit #2 Control Transformer FireUnit #2 Control Transformer Fire
33ppm
Harrington Energy ServicesHarrington Energy Services
•• Existing Fire Protection systemsExisting Fire Protection systems
•• Mixture of 1970’s High Expansion Mixture of 1970’s High Expansion Foam systems & dry pipe systems on Foam systems & dry pipe systems on all above ground conveyorsall above ground conveyors
•• High Pressure COHigh Pressure CO2 2 •• Dry Pipe in Crusher HouseDry Pipe in Crusher House•• Deluge in Reclaim Tunnel (newer Deluge in Reclaim Tunnel (newer
addition)addition)
Old Foam SystemIn 400/410 Gallery
Old Foam SystemUnit #3 Tripper Deck
Old Dry Pipe SystemOn Unit #1 Tripper Deck
High Pressure CO2 System
Harrington Energy ServicesHarrington Energy Services
•• Replacement Fire Protection System:Replacement Fire Protection System:
•• Budgetary approval Budgetary approval –– 20032003•• Phased project approachPhased project approach•• Conveyors: Deluge Based Design Conveyors: Deluge Based Design •• Dust Collectors (FDust Collectors (F--500 supplemented)500 supplemented)•• Sampler building: Dry Pipe Sampler building: Dry Pipe •• Crusher House: Auto fire hose Crusher House: Auto fire hose
standpipe systemstandpipe system
Harrington Energy ServicesHarrington Energy Services
•• Project EngineerProject Engineer
•• The Utility FPE Group, Inc.The Utility FPE Group, Inc.•• Years of practical inYears of practical in--plant experienceplant experience•• PRB coal expertisePRB coal expertise•• Practical approachPractical approach•• OutOut--ofof--thethe--box design applicationsbox design applications
•• Concept DevelopmentConcept Development•• Design Specifications Design Specifications •• Contractor Bid EvaluationContractor Bid Evaluation•• Contractor Drawings ReviewContractor Drawings Review•• Inspection of Contractor Work for Quality ControlInspection of Contractor Work for Quality Control
Harrington Energy ServicesHarrington Energy Services
•• Replacement Fire Protection System:Replacement Fire Protection System:
•• Concept Development: AprilConcept Development: April--JuneJune•• System Design Engineering: JuneSystem Design Engineering: June--
AugustAugust•• Contractor Bid Process: AugustContractor Bid Process: August--Sept Sept •• Project Awarded: SeptemberProject Awarded: September•• Project StartProject Start--up: December 2003up: December 2003
Rigorous Design Specifications
Extensive Contractor Evaluation Process
Harrington Energy ServicesHarrington Energy Services
•• Replacement Fire Protection System:Replacement Fire Protection System:
•• Current Technology DetectionCurrent Technology Detection•• Linear Heat DetectionLinear Heat Detection•• Strategic Spot Thermal Detection Strategic Spot Thermal Detection •• Full System CO MonitoringFull System CO Monitoring•• Strategic Infrared DetectionStrategic Infrared Detection
Infrared DetectionInfrared DetectionStrategic Locations In ReclaimStrategic Locations In Reclaim
Harrington Energy ServicesHarrington Energy Services
•• Replacement Fire Protection System:Replacement Fire Protection System:
•• Suppression ConceptsSuppression Concepts•• DelugeDeluge--water where you need it water where you need it
when you need itwhen you need it•• Tail & Head Chute ProtectionTail & Head Chute Protection•• “Car Wash” Concept in Tripper “Car Wash” Concept in Tripper
Galleries Galleries ––Targeted coverage with Targeted coverage with minimum flowminimum flow
“Car Wash” Concept“Car Wash” ConceptDirect Conveyor ProtectionDirect Conveyor Protection
Zoned For Involved Conveyor OnlyZoned For Involved Conveyor OnlyMinimize Water VolumeMinimize Water Volume
New Valve StationAt Unit #3 TripperDeck area
Replacement ValveSystem at PumpHouse Area
Scott
ReplacementPumphouse
& Lower ValveManifolds
New Sampling SystemBuilding & Storage area
ReplacementCrusher BuildingBaghouse
Piping Installationalong 240/250 conveyors
Piping installation along 240/250 Conveyors
Spray head installation along 240/250 Conveyors
Piping installation along 400/410 Gallery conveyors
Old MCC RoomUnit #1 Tripper Deck area
Replacement MCC Room located outsidethe Unit #1 Tripper Deck area
Old Dust Collector On Unit #1
Replacement Dust Collector installedon Unit #1
Structural Steel & Placement of Replacement Dust Collector on Unit #3.
Harrington Energy ServicesHarrington Energy Services
•• Fire Prevention:Fire Prevention:
•• Frequent system inspectionsFrequent system inspections•• Daily system washdownDaily system washdown•• Material control & containmentMaterial control & containment•• Pile managementPile management•• Team Member awarenessTeam Member awareness•• Early Warning Detection SystemEarly Warning Detection System
Harrington Energy ServicesHarrington Energy Services
•• Safety:Safety:•• Active Participant in Integrated ERT Active Participant in Integrated ERT
Team Team Xcel Harrington/Nichols Xcel Harrington/Nichols -- SavageSavage•• One Team Member is strategically One Team Member is strategically
placed on each Teamplaced on each Team•• ERT Training includes EMT certificationERT Training includes EMT certification
Structural Fire Team With Hands-On Coal Handling Fire Training
Scott
Savage-HarringtonSavage-Tolk