coal handling systemcoal handling system fire protection ...c.ymcdn.com/sites/ · coal handling...

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 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 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


•• 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


•• 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


•• 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


•• 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


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


•• 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



•• 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



•• 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


•• 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


•• 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


•• 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



•• 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



•• 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



•• 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.


•• 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


•• 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

coal handling systemcoal handling system fire protection ...c.ymcdn.com/sites/ · coal handling...

Documents