Their challenge

When this client began planning for a major refurbishment project at one of their key power generation facilities, they knew there would be design challenges. They requested Salas O’Brien to oversee various elements of the project, including refurbishment of a ball mill and its major mechanical components; design and supply of electrical components for the ball mill and limestone unloading, storage, and reclaim systems; and automation and controls design. One of the owner’s goals was that these designs utilize as many existing components as possible while still ensuring safe and efficient operation.

Our solution

Our team followed a process of thorough testing to verify the integrity of older components before integrating them with newer components in our design. Our design work included specification for a new 1250 hp motor to drive the refurbished ball mill, a new semi-automated ball charging system, and new and updated piping for affected systems. We also specified, designed, programmed, and supplied all control system components and provided Programmable Logic Controller (PLC) and Human Machine Interface (HMI) programming and integration.