Public Power Utility Company
Power Generation Facility Ball Mill
This client entrusted Salas O’Brien with engineering, procurement, and construction supervision for a significant part of a refurbishment project at one of their key power generation facilities. The project involved design for mechanical components of an important ball mill as well as electrical design for various supporting systems and controls. Our thorough integration of old and new elements radically reduced the owner’s capital costs while still ensuring each systems’ safe and efficient operation.
This Public Power Utility Company is a community-based, not-for-profit water and energy company in Arizona that delivers consistent, cost-effective service to its over 2 million customers. It is also one of largest public power utilities in the country.
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 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, and supplied all control system components and provided Programmable Logic Controller (PLC) and Human Machine Interface (HMI) programming and integration.
The finished systems successfully incorporated new mechanical elements including a high pressure bearing lift system, a smart gear lube spray system, mill shell liners, and newly machined bull and pinion gears. Our successful integration of older components radically reduced our clients capital costs while ensuring that each of the systems operates safely and efficiently. To verify, our team also performed a Factory Acceptance Test (FAT) with complete I/O simulation in the presence of the client to confirm the systems were running smoothly.