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  • PF Pipe Leakage Repairs

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    The document discusses coal pipe leaks at the Jeffrey Energy Center power plant and the plant's response. The plant has three 800MW coal units that use PRB coal. Coal pipes running from the coal mills to burners are over 2,500 feet long and have started leaking, causing dust, fires and maintenance issues. To address this, the plant developed a leak response plan that includes inspections, temporary repairs, wash downs and a 5-year capital plan to replace sections of aging coal pipe on each unit to prevent future leaks.

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    repair technology of Pulverized coal pipes

    Original Title

    PF pipe leakage repairs

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    The document discusses coal pipe leaks at the Jeffrey Energy Center power plant and the plant's response. The plant has three 800MW coal units that use PRB coal. Coal pipes running from the coal mills to burners are over 2,500 feet long and have started leaking, causing dust, fires and maintenance issues. To address this, the plant developed a leak response plan that includes inspections, temporary repairs, wash downs and a 5-year capital plan to replace sections of aging coal pipe on each unit to prevent future leaks.

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    © All Rights Reserved
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    18 views9 pages

    PF Pipe Leakage Repairs

    Uploaded by

    DSG
    The document discusses coal pipe leaks at the Jeffrey Energy Center power plant and the plant's response. The plant has three 800MW coal units that use PRB coal. Coal pipes running from the coal mills to burners are over 2,500 feet long and have started leaking, causing dust, fires and maintenance issues. To address this, the plant developed a leak response plan that includes inspections, temporary repairs, wash downs and a 5-year capital plan to replace sections of aging coal pipe on each unit to prevent future leaks.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 9

    www.PRBCoals.com I www.PRBCoalsForum.

    com I 2011 Conference


    Coal Pipe Leak Repairs
    Presented By:
    Dave Stubby
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    (3) 800MW Units
    8 Corner T-Fired
    CE Boilers
    Siemens Turbine-
    Generators
    (7) CE RP1003
    Bowl Mills
    100% PRB Coal
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    Coal Pipe (riffle to burners)
    18 diameter
    thick
    2,577 feet per unit
    250,000,000 tons of
    PRB coal burned to-
    date.
    Original Installation
    1978-Unit 1 1980-Unit 2 1983-Unit 3
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    Coal Pipe Leaks
    Created:
    Unacceptable
    Housekeeping
    Combustible Dust
    Compliance Issues
    Root Cause of Cable Tray Fires
    $50k/year in emergent parts & labor
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    Response Plan
    Quickly remove coal mills from service when
    leaks are identified.
    Develop a leak repair procedure.
    Develop a wash down / cleaning response.
    Develop a 5-year Capital plan to replace
    coal pipe
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    Inspectforleaksevery8hours
    Continueoperatorinspections
    No
    Istherealeak?
    Yes
    Isablastpaneldirectedinthe
    areaoftheleak
    Yes
    No
    Makeatemporaryrepair.
    WriteaP4WOforpermanent
    Repair
    Cantheleakbestoppedbythe
    operatorwithin30minutes?
    Yes
    No
    Washdowntheareawithin1
    day
    CROremovesmillfromservice
    Makeweldrepair Returnmilltoservice
    Maintenanceaccessestherepair CROwritesaP5WO
    Washdownthearea(HotWork)
    Washdowntheareawithin1
    day
    Orderscaffold
    Yes
    Isscaffoldneeded?
    OperationsSupervisorverbally
    notifiesMaintenance
    Weld
    Whattypeofrepairisneeded?
    Wrap
    Wrapcoalpipe
    Scheduleddispatcherderate
    Yes Canatemporarypatchbe
    applied?
    No
    Isscaffoldneeded?
    Yes
    Orderscaffold
    Makeweldrepair
    Weld
    Whattypeofrepairisneeded?
    Wrap
    Wrapcoalpipe
    Returnmilltoservice
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    106 coal mill coal pipe
    leak
    Temporary patch of
    welding blanket and
    RTV.
    Permanent patch of
    fiberglass wrap.
    Labor costs for 10-hours
    = $526.58.
    Parts & materials cost =
    $444.88.
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    Response Plan
    Develop a 5-year Capital plan to replace
    coal pipe
    CoalPipingMultiYearReplacementPlan
    2010 2011 2012 2013 2014 PerUnitCost
    Unit1 AboveRiffles $1,481,276.00 $3,822,856.00 $5,304,132.00
    Unit2 AboveRiffles $2,414,925.00 $800,000.00 $1,800,000.00 $5,014,925.00
    Unit3 AboveRiffles $2,212,627.00 $2,500,000.00 $4,712,627.00
    $2,212,627.00 $3,896,201.00 $3,822,856.00 $3,300,000.00 $1,800,000.00 $15,031,684.00
    www.PRBCoals.com I www.PRBCoalsForum.com I 2011 Conference
    J effrey Energy Center
    Questions
    Unit 2 & 3 Coal Pipe Replacements

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