Case Study: Coal Fired Steam Boiler Baghouse Maintenance Project
IAC evaluated a baghouse rebuild project to review a 16-module reverse air structural baghouse. The original scope of the inspection was to evaluate the baghouse for needed repairs due to concerns over corrosion that had taken place over the years, as well as overall baghouse performance. This baghouse collects fly ash off of the plant’s coal-fired boilers, which are used to generate steam for the needs of the plant.
A detailed inspection report was generated and sent to the customer. The report included a list of recommendations for a scope of repair work. A substantial portion of these recommendations included the replacement of numerous dampers on the baghouse, as well as the reverse air ductwork. Follow-up meetings were held at the plant to discuss various option for upgrading the baghouse equipment or possible converting it to a pulse-jet. The customer reviewed our recommendations and focused on the damper and duct repair as items to get approved for a baghouse rebuild project.
Several months of internal discussions within the plant took place to further define the project. IAC provided budgetary equipment and labor pricing. IAC went through the documentation process with the customer to become an official “approved contractor”. The insurance and safety requirements were substantial. IAC was certified as an approved contractor.
IAC provided all supervision, safety management, labor, tools, crane, forklifts, scaffolding, and materials. IAC’s wholly-owned construction subsidiary, Adelphi Construction LC, provided all project installation manpower, including project manager, shift supervisors, safety manager, foreman, welders, pipefitters, rigger, firewatch, helpers, and confined space attendants.
The safety standards and procedures at the jobsite were extremely rigorous. Each shift was required to obtain Daily Work Permits from the Safety department for each task being performed on that shift. Separate Confined Space Entry Permits were also required. Each application for a Work Permit had to be accompanied by a thorough Job Safety Analysis Form, which was completed by the Adelphi Safety Manager. The Safety Manager did an excellent job of complying with all plant safety requirements and paperwork, as well as daily safety meetings with the Adelphi crew. His work also included overseeing the safety permitting of IAC subcontractors.
The results were excellent: Over 10,000 man-hours were worked without a single injury of any sort. IAC and Adelphi were praised by the plant Safety Department personnel for exceeding plant safety standards and being exceptional in adhering to the documentation and work permit requirements. All work was performed within the customer’s allotted schedule.