Brunner Island OSHA Dust Consulting

Client

PPL Generation
Two North Ninth Street
Allentown, Pennsylvania 18101-1179

Completion Date

February, 2011

Project Description

PPL Generation is a subsidiary of PPL Corporation, an energy and utility holding company that generates electricity from power plants in Pennsylvania, Kentucky, and Montana; markets electricity in the northeastern and northwestern United States; and delivers electricity and natural gas to 2.7 million customers in Pennsylvania and Kentucky and 7.6 million customers in the United Kingdom. Coal-fired generation accounts for about 9,700 MW of PPL’s total of about 19,000 MW of generating capacity.

PPL Generation has recently upgraded both the 1,483 MW Brunner Island coal-fired power plant in York Haven, Pennsylvania, and the 1,552 MW Montour coal-fired plant in Washingtonville, Pennsylvania with new air quality control systems (AQCS). The $800 million scrubber, Unit 2 electro static precipitator and cooling tower addition at Brunner Island and the $600 million scrubber addition at Montour include new limestone receiving, storage, and handling facilities. New cooling towers were added Brunner Island to minimize the thermal impact of wastewater discharges to the Susquehanna River. These investments demonstrate PPL Generation’s continued commitment to customers, technology improvements, and environmental compliance.

As a continuation of the plant upgrade program, PPL Generation similarly initiated an upgrade to the coal handling systems with an OSHA Dust Control program. The chutes at Brunner Island, which were originally provided by Robins Engineers in 1964 with an addition provided by Fairfield Engineering in 1978, were completely replaced and new dust suppression systems were added. This upgrade was also done at Montour along with enhancements to other coal handling system components.

PPL engaged Energy Associates to assist PPL during the commissioning phase of the OSHA Dust Control System and to identify potential enhancements. As part of this effort, the design of the original chutes, design of the new chutes, coal quality, materials of construction, chute and conveyor design parameters were examined. The new chutes were observed in an operating and non-operating condition, plant personnel were interviewed for their input and experience, and contractor submittals were evaluated. Energy Associates prepared and submitted to PPL a dozen memo reports on issues as the investigation progressed and improvements completed.