Site Steam Generation
Everett, based client achieves isolation of single module group shutdown.
This leading Seattle based Aerospace company needed to upgrade its aging site steam generation equipment at their Everett, WA campus. The approach to the site’s steam generation needed to be modified for higher reliability and to allow for maintenance of equipment, without affecting the overall steam production capabilities in support of production.
These shutdowns, either planned or unplanned, could jeopardize production because the winter steam demand of 300,000 Ibm/hr could not be reliably supported by the standby boilers.
How We Did It
Harris Group’s approach was to modularize the steam system which allowed for isolation of any module group for shutdown at any time without affecting the overall steam production capabilities of the remaining two module groups.
Harris Group designed the renovation of two boiler plants that supply our client’s Everett, WA campus. The steam generation system was modified to provide three module groups of two boilers each with support piping, auxiliary equipment and controls modifications. This module approach allowed isolation of any module group for shutdown at any time without affecting the overall steam production capabilities of the remaining two module groups. Each module group contains all auxiliary equipment needed to be completely isolated such that no single point of failure of one group will affect the other two groups.
Safety is key for our client and Harris Group. Our Harris Group team provided Multiple Energy Source (MES) isolation placarding to this highly complicated project. The placarding for the steam plant modules was more challenging than typically encountered equipment. We were asked to evaluate the equipment on multiple levels. Some equipment was to be placarded as standalone equipment. Other equipment was part of a larger system and did not need an individual placard. Where shut down of a specific piece of equipment would shut down a larger system or the entire module it was included within the MES placard for isolation of the larger system or the module. Preparation of the placards for the steam plants required a complete understanding of the processes and equipment.
Our Harris Group team provided Multiple Energy Source (MES) isolation placarding to this highly complicated project.
Much of the aging boiler auxiliary and support equipment in the 40-12 Building had reached the end of its useful service life and the equipment was replaced to assure a reliable supply of steam into the future.
The primary steam supply is from Boiler Nos. 1 through 4 in the 40-12 Building. The secondary supply is from Boiler Nos. 5 and 6 in the 45-07 Building. These units are natural gas-fired, with No. 2 fuel oil as backup. The original nameplate rating for all six boilers was 125,000 lbm/hr. Boiler Nos. 1 through 4 shared common equipment, such as the deaerator tank, condensate tank, flash tank, UPS system, and feedwater and condensate pumps. These shared equipment systems were inherent single points of failure, which could force a shutdown of these four boilers jeopardizing aerospace production.
The three module configuration maintains critical steam production, during a planned or unplanned shutdown with two operating modules to support the winter steam demand of 300,000 lbm/hr. Our services included detailed P&ID development and detailed design and controls drawings. The steam, condensate, feedwater, and fuel oil piping was completely reworked in both steam plants. The 40-12 building contains two module groups and the 45-07 building contains the remaining module group. The 40-12 boiler plant also included seismic upgrades and fire protection design.
Harris Group provided project management; mechanical process piping, P&ID, instrumentation, HVAC, plumbing, fire protection architecture, electrical, and structural engineering. The project included removal, reconfiguration, and replacement of virtually all boiler support equipment and piping systems, as well as complete replacement of all instrumentation, and control systems, including chemical injection systems. Harris Group was also the commissioning agent for this project ensuring the facilities operated as
