Failure Investigation of FAM’s Scraper Reclaimer
1,230 MWe Elm Road Power Plant

Client

Bechtel Power Corporation
5275 Westview Drive
Frederick, MD 21703-8306

Completion Date

October, 2008

Project Description

Bechtel constructed the 1,230 MWe Elm Road Generating Station for We Energies. This $2.15 billion lump sum project was the largest in Bechtel’s history. Elm Road will is one of the most efficient coal-fired power plants in the world, with once through cooling and a supercritical boiler.

The plant uses PRB coal, which is reclaimed by a portal scraper reclaimer that was designed and manufactured by FAM Magdeburger Foerderanlagen und Baumaschinen, GmbH (FAM). The reclaimer and an enclose stockpile building were constructed as part of Bechtel’s Elm Road project. The reclaimer is the primary device used to deliver coal to:

1. the two (2) new Elm Road units and

2. the existing four (4) units of the South Oak Creek Plant.

The reclaimer was completed ahead of the start-up date for the Elm Road Generating Station, so it could begin delivering coal to the South Oak Creek Plant and reduce fugitive dust emissions from mobile equipment operations on the uncovered stockpile. This reclaimer experienced recurring problems. FAM’s modifications were unsuccessful and the emergency reclaim system had to be used to fuel the South Oak Creek Plant. Bechtel Power engaged Energy Associates to provide consulting services to investigate the reclaimer failure. Energy Associates:

1. observed the FAM reclaimer on multiple occasions while FAM continued its repair efforts;

2. reviewed numerous technical documents submitted by FAM to Bechtel;

3. requested additional information on the Elm Road reclaimer, similar/operating FAM reclaimers;

4. investigated design details, including chain tensions and features used for the chain;

5. prepared a preliminary report of findings, which Bechtel submitted to FAM; and

6. met with FAM, Bechtel, and We Energies at FAM’s Magdeburg, Germany offices in a series of meetings to develop a satisfactory repair solution.

The repairs conceived in Magdeburg were more extensive than previously initiated by FAM. A short section of chain on one of the main booms was modified and tested in December 2008. The necessary components where then manufactured for the both main booms and the repair completed April 2009, nearly one-year after the original commissioning date for the reclaimer.