Results


Solution & Implementation

Working within the one-month deadline, Furmanite quickly developed and implemented a concrete solution. This included placing the most experienced concrete services specialists on the job and using the most effective concrete materials, which would allow the project to be completed within the allotted time. Furmanite is not affiliated with any OEM suppliers, allowing customers to choose the most optimum solutions and a variety of repair products.

“We relied on Furmanite’s experience, understanding the required project timeline and our desired results to provide us with the best materials at the lowest price,” said Thomas Roberts, the PacifiCorp-assigned Project Engineer.

Furmanite concrete specialists began by cutting and removing the damaged concrete. The next step entailed replacing the old reinforcing steel with new steel. New concrete was then formed and poured.

The second phase of Furmanite’s solution required a specialist to apply a coating on the bottom 10 feet. Furmanite selected a fast-setting concrete that would cure and hydrate quickly. The bottom 10 feet was then coated with an abrasive-resistant durable coating. This process created a very slick area at the lower portion of the hopper, allowing the coal to slide easily.

Case Study: Concrete Repair

Furmanite Beats PacifiCorp’s Tight Deadline Providing Unique Concrete Solution for Coal Facility

After 30 years of wear and tear on a concrete slot storage barn, PacifiCorp was faced with a facility in serious need of quick repair. To accomplish the task, PacifiCorp, which owns and operates the Huntington Canyon Plant, asked Furmanite, a worldwide technical and engineering services company, to get the job done within a very short time. The project had to be completed when coal deliveries to the barn could be minimized, allowing the concrete slot storage to be worked on in sections.

Call to Action

After years of providing leak sealing, machining, and valve repair services to PacifiCorp and then winning the competitive bid, Furmanite was called on to repair the 30-year-old concrete slot storage coal barn at PacifiCorp’s Utah facility. The coal barn serves as a multi-day storage facility and rudimentary fuel blending facility. The barn is about 450 feet long and has a roof over the slot storage reclaim area. A rotary plow pulls the coal from the barn onto a conveyor for transport to the power plant. The coal is dropped from above the slot storage with a conveyor belt moving tripper suspended beneath the barn roof.

The challenge Furmanite faced was repairing severe damage to the concrete slopes and slot openings to the rotary plow in the bottom of the barn slot, which was caused by large track dozers hitting the sides of the structure while pushing into and out of the barn.

“The damage to the PacifiCorp coal barn was even more severe than originally anticipated or inspected,” said Tim Coughlin, Furmanite’s Concrete Services Specialist who oversaw the project. “And, the job was especially challenging because the work had to be completed during the one month period when coal deliveries were suspended for planned mining maintenance.”

The coal barn was originally designed to allow the coal to slide down the steep side slopes to the slot above the rotary plow feeder and conveyor area. However, the original concrete slumped and created a “shelf” at the bottom of the slope, instead of a continuous 50 degree slope which would allow the coal to slide freely. This prevented the coal from sliding and caused it to rest on a ledge at the slot. Significant sagging of the side slope areas caused the joints to open, allowing water to seep behind the concrete, causing wash outs and rusting of the reinforcing steel. As a result, the concrete was significantly cracked and falling apart.

Results

When originally bidding the project, PacifiCorp and Furmanite estimated the quantity of work, realizing that it could change because only a small portion of the barn slot was available for evaluation prior to the work. The actual project increased nine-fold due to unforeseen damage to the concrete. Furmanite met the challenge by quickly increasing its work force at the plant and obtaining the necessary materials in order to meet the deadline.

As a result, the PacifiCorp project was completed approximately two days ahead of schedule. Furmanite’s concrete solution created a process which was faster and more efficient and, as demonstrated at PacifiCorp, ultimately can lead to a plant’s increase in production and operation.

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On-Line Leak Sealing

Our leak-sealing technology and unrivaled
on-site service help you maximize asset uptime
by sealing leaks online, onsite and under pressure. This means you keep producing the ‘product’ while we solve your leak problems.

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Hot Tapping

At Furmanite we carry the largest and most diverse inventory of Hot Tapping equipment
in the world. We have a proven record of developing unique and custom Hot Tap solutions for the most complicated scenarios.

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Line Stopping & Plugging

Our Line Stopping services help prevent unwanted shutdowns and keep critical piping
and pipeline systems online during tie-ins, relocations, repairs, retrofits and routine maintenance.

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On-Site Machining

Our portable machining tools deliver the benefits of a fully equipped machine workshop on-site – where our clients need it most. We consistently achieve tolerances and finishes usually only achievable in a machine shop.

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Self Leveling Machines

Furmanite’s Self Leveling Machines deliver precision on-site machining for large circular and irregular shaped surfaces. Our circular and linear machining equipment is portable and ready for global deployment.

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Composite Repair

Our range of composite repair solutions is designed to ensure the ongoing structural integrity and load-bearing capabilities of your assets, improving their longevity whilst minimizing the impact on your productivity.

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Post Weld Heat Treatment

Furmanite offers a full range of heat treatment services through a wide range of temperatures. We manufacture, own and operate the most technologically advanced heat treatment equipment available in the marketplace.

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All Services

We offer a comprehensive range of on-site
and on-line plant and pipeline maintenance services. From standard applications to highly customized solutions our goal is to help you maximize your asset up time.

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Hot Tapping

Furmanite has been manufacturing Hot Tapping equipment for over 50 years. Our Hot Tapping Machines ensure your critical piping systems maintain a continuous flow while installing new tie-ins and branch connections.

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Line Stopping & Plugging

For over 50 years Furmanite’s Line Plugging equipment has been helping clients maintain a continuous flow on critical piping systems while performing repairs, relocations, valve or pump installations and pipe modifications.

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Pipeline Repair Products

We have a wide range of Pipeline Repair
and Integrity products designed to handle emergency leak repairs in high pressure environments and improve the structural integrity and safety of your pipelines.

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Portable Machining Tools

Furmanite’s Silk portable and lightweight machine tools provide high tolerance solutions for a variety of problems. Renowned for their sound engineering, our Silk machines help you deliver precision onsite machining.

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Valve Products

The Wilson Snyder Switch Valve has provided proven reliability for over 75 years in Coker Switch Valve applications. Wilson Snyder Switch Valves have the lowest steam consumption in the industry.

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Health & Safety Products

We offer a wide range of proprietary Safety, Environmental and Maintenance products designed to eliminate injuries and improve pipeline safety. At Furmanite, your ongoing safety is our number one priority.

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Chocking Prevention

Furmanite’s SmartShim™ is a truly effective and state-of-the-art conductor analysis and chocking solution that will ensure your offshore production site remains productive, powerful and profitable.

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All Products

Furmanite has been a trusted resource for sophisticated engineering products for over
75 years. From Hot Tapping to Line Stopping, we have a wide range of products to meet your pipeline repair and maintenance needs.

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Industries

Furmanite is a world leader in the provision of on site services to clients in the mining, petro-chemical, off shore, oil & gas, powergen, marine, pulp & paper and general engineering industries globally.

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Case Study: BAE Systems Airbus

To overcome the need to remove the plateaux (part of the wing) to be milled flat for a precise fit, as well as avoiding the risk of distortion when re-fitted to the aircraft.

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Case Study: Esso Fawley Refinery

Esso’s unit 1 boiler at Fawley was shutdown for repair. The unit 2 boiler had developed a superheater tube leak. The challenge was to carry out a repair, the alternative was a shutdown of the major processing units.

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Case Study: Major Operator

The customer wanted to modify their petrochemical plant – but they didn’t want to shutdown.

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The original configuration of pipe-work on the North Cormorant platform of the Otter over Eider project, did not lend itself to the increased flow.

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Case Study: Nuclear Electric

Accurate and reliable valve testing was required in quick time as part of the pre-commissioning process.

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Case Study: Shell Expro Gannet Platform

When Shell United Kingdom Exploration and Production (Expro) introduced a new Induced Gas Floatation Unit (IGFU) onto their Gannet platform they had planned to finalise the installation during a 30-hour shutdown.

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