COOP END OF TERM PRESENTATION

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CO-OP END OF TERM PRESENTATION

• SPRING/SUMMER 2008

BY CAMERON MOSER
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OVERVIEW

• PRIMARY ENGINEERING DIMENSIONS
• STORMWATER PROJECT
• SLAG DEWATERING PROJECT
• MISCILLANEOUS ACHEIVEMENTS
• LESSONS LEARNED
• CONCLUSION

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Primary Engineering Dimensions

• Safety
• Project Management Practices
• Documentation
• Construction Support (QA)
• Application of Engineering Principles
• Professional Development

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Storm Water Project
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Storm Water Project
Process Diagram
WEST Coal Field
East Plant
Plant Area
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Storm Water Project
Process Diagram

• Provide Operations
• Overview of system flow during normal and
  emergency conditions
• Location of sumps pumps
• Location of pump breakers for maintenance
  purposes

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Storm Water Project
Level Control Calibration

• Provide Construction Operations
• Specifications of sump
• Start/stop levels for multiple pumps
• Visual aid in calibrating level control
  transmitter
• Calibration chart with detailed levels and their
  associated milliamp readings

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Storm Water Project

• Primary Engineering Dimensions
• Project Management
• Coordinated and led meetings
• Scheduled walk downs of sumps
• Document Control
• DWR
• Arranged PIDs, pump specs/manuals, and drawings
  into turnover packages to be used by start-up.
• As - Builts
• Construction Support (QA)
• Level Control and Calibration
• Performed walk downs of sumps
• Application of Engineering Principles
• Conducted flow tests on Sump-011 for orifice
  sizing

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SLAG DEWATERING PROJECT
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Slag Dewatering Project
Process Diagram

• Provide Operations
• Overview of system flow during normal and
  emergency conditions
• Location of key equipment

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Slag Dewatering Project
Testing, Start - Up, Troubleshooting

• Provide Operations
• Checklist to monitor system operation
• Familiarization with buttons and readings
• Detailed, graphical description of step-by-step
  process

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Slag Dewatering Project
Simulated Run
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Slag Dewatering Project

• Examples of problems found
• Lag pump failed to initiate after lead pump trip
• Valves failed to align during certain functions
• Misleading ,unclear, and incorrect labels on HMI
• Some HMI buttons were of little or no practical
  use
• No indication of power or communication failure
• Chatter or the rapid activation and
  deactivation of pumps from interaction with each
  other

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Slag Dewatering Project
Testing, Start - Up, Troubleshooting

• Solving Chatter
• Using trend function, amp readings were used for
  analysis
• Data shows spiking of amps upon activation or
  deactivation of lag pump, resulting in chatter
• Problem could be solved in PLC

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Slag Dewatering Project
Testing, Start - Up, Troubleshooting

• Solving Chatter
• Problem solved by adding delay timers before pump
  activation / deactivation in PLC logic

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Slag Dewatering Project
Testing, Start - Up, Troubleshooting
Solving Chatter
BEFORE
AFTER
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Slag Dewatering Project
Minimum Flow Bypass Orifice Sizing Calculation

• Designed to meet minimum flow conditions
• Associated measures, constants, equations, and
  frictional factors were used. Cameron Hydraulic
  Data and Crane were consulted to determine these
• Pump hydraulic curves were referenced to
  determine head losses

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Slag Dewatering Project
Minimum Flow Bypass Orifice Sizing Calculation

• Simplified Using Excel
• Changing of different variables lead to redundant
  calculations
• Flow properties of different cases easily
  explored using macros in excel
• Regression with equation used to estimate values
  and iterate

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Slag Dewatering Project

• Primary Engineering Dimensions
• Safety
• Submitted safety suggestion to install life
  support atop the bins.
• Project Management
• Devised test regimen for return water and
  overflow pumps
• Assisted Allan Sherman-Hoff representative in PLC
  reconfiguration
• Created and implemented log for use by operations
• Document Control
• Compiled and organized drawings for slag
  dewatering system
• Updated redundant line drawing using AutoCAD
• Construction Support (QA)
• Ordered and tracked shipments from vendors
• Administered tests on return water and overflow
  pumps while recording necessary punch-list items
• Reviewed and marked up drawings submitted for the
  minimum flow bypass line
• Application of Engineering Principles
• Calculated orifice size for minimum flow bypass
  line

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Miscellaneous Achievements

• Primary Engineering Dimensions
• Safety
• Completed safety training course
• Provided safety tips at meetings
• Professional Development
• Scheduled to take Hudson Pump Centrifugal Pump
  Seminar
• Attended various Lunch and Learn meetings
• Construction Support (QA)
• Performed piping takeoffs for Recycle Pond
  Project
• Calculated fill volume for settling pond and
  removed CCPs
• Application of Engineering Principles
• Performed walk down inside UNIT-3 Boiler for
  fault inspections

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Lessons Learned

• Safety First
• See the Big Picture
• Teamwork
• Have a Plan
• Define Expectations
• People must Buy in
• Take Initiative

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Special Thanks

• Jamie Arenas
• George Bolos
• Asa Cuellar
• Eid Dahdal
• Jerid Fortney
• Jessica Helkin
• Brit Johnston
• Sonny Miller
• Yogesh Patel
• Fred Wyly
• Troy Yambura
• Fellow CO-Ops - Allan Morales, Sabri Fattah,
  Johel Comas, Tyson Dabney, Joseph Maydell

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Conclusion

• Questions/Comments after Allans Presentation