Problem
The Warrick Power Plant is operated by the Alcoa Generating Company to supply electricity for smelting operations at Alcoa’s Warrick facility. The plant’s coal handling equipment needed reconstruction and improvement, including enhanced systems to control spillage and dust, to provide a cleaner, safer and more productive coal handling system.
Solution
The Martin® Service crew performed the reconstruction of all 16 transfer points in the Warrick Power Plant coal handling system. The actual working time was roughly nine weeks, but to avoid any interference with Alcoa production schedules, it was performed during the plant’s periodic schedule of outages over a six-month period.
At each transfer point, the project included:
- Removal of existing chute walls and skirtboard
- Removal of existing idlers and impact roll assemblies
- Installation of new chute wall with supports, covers, and Martin® Wear Liner
- Installation of Martin® Slider Cradles with center support rollers
- Installation of Martin® ApronSeal™ Skirting with clamps
- Installation of a Martin® Tail Sealing Box
- Installation of Martin® Dust Curtains and Martin® Dust Bags
Additionally, the work included the removal of the existing chute and flop-gate assembly. Martin® Service crews field-fabricated stainless steel pulley guard assemblies for the 10 conveyors in the coal handling system.
Results
The transfer point reconstruction project has dramatically improved plant conditions by controlling dust, eliminating material spillage, and improving belt tracking. The Martin® Service crews received high marks for their efforts from Warrick Plant personnel.
