This document summarizes three projects managed by Kevin Brock as a project manager. The first project involved replacing fan components for two induced draft fans to address degradation. The second involved inspecting and replacing cracked welds in a main steam pipe system. The third involved upgrades to a limestone handling system to address equipment degradation and issues with the changed material being handled. All three projects were completed under budget and provided reliable systems that exceeded requirements.

1. Kevin Brock, PE, PMP – Mechanical Engineer & Project Manager kevin.b.brock@gmail.com
Induced Draft Fan Project
Role: Project Manager
Responsibilities: Project evaluation, justification and charter development; created technical specifications for
bid; stakeholder engagement, contractor/equipment selection; installation & construction
management personnel oversight; project closeout & documentation.
Scope: The scope of this project included replacing the fan shafts, fan housings, shaft seals, outlet
dampers, inlet and outlet expansion joints, and, inspecting and refurbishing the fan wheels for
2 ID fans.
Background
and Conditions
Flue gas from the boiler is drawn through the SCRs and precipitators by the ID fans and then
pushed through the scrubber to the stack. The fans suffered considerable degradation due to
acid corrosion as a result of the formation and deposition of H2SO4 from the flue gas onto the
steel parts of the fans, aided by poor seal design and maintenance.
Statement of
Problem/Opportunity
The ID fan shafts were near the end of their useful life. The shaft diameters had degraded
over time and were close to the minimum allowed by the OEM guideline. The fan housings
were also degraded and patching had become more and more expensive. Operating guidelines
required operation of both ID fans when the unit is online, so if one fan failed the entire unit
would be offline until repairs were completed. It would take an estimated 12 weeks to replace
a fan shaft and repair casing damage resulting from a fan shaft failure. Such an event is also a
considerable safety concern.
Key Outcomes: Project was completed under budget providing a reliable system exceeding requirements.
Drawings & Pictures:
Figure 1: Project area during construction. Note the duct,
dampers, and fan housing have been replaced. Rotor is
staged to be installed in housing and insulation and lagging
has not started.
Figure 2: Installation of one of the fans into the housing.
The fan wheels were refurbished and pressed onto new
shafts. The assembly was then balanced in the shop and
sent to the site for installation in the housing.

2. Kevin Brock, PE, PMP – Mechanical Engineer & Project Manager kevin.b.brock@gmail.com
Main Steam Pipe Project
Role: Project Manager
Responsibilities: Project evaluation, justification and charter development; created technical specifications for
labor and material bids; stakeholder engagement, contractor selection; installation &
construction management personnel oversight; project closeout & documentation.
Scope: The scope of this project included inspecting the high energy pipe system & replacing 32 welds
in the main steam pipe system at a coal fired power plant.
Pipe specs:
27” (nominal OD) seam less alloy steel, SA335 P22, 4.375” min wall, 18.125” min ID
21” (nominal OD) seam less alloy steel, SA335 P22, 3.375” min wall, 14.125” min ID
Elbows:
Qty 2: 90o
– 36’ & Qty: 2 90o
, 21.00” (Nominal OD), Seamless Alloy Steel, SA234 WP22, 3.375”
min wall after fabrication, 14.00” min ID , 31.5” Radius, six inch additional tangent length
Background
and Conditions
Steam from the boiler flows to the turbine through the main steam pipe system. Steam
conditions are 1005 o
F at 2400 psia.
Statement of
Problem/Opportunity
During a previous outage 14 welds in the main steam pipe system were identified to be
cracked with depths on some at 1”. To repair this condition it was decided to cut spools out
around the known cracked welds and replace with new pipe sections. Also, during this outage
the remaining welds were inspected with numerous welds found in need of replacement,
which were all addressed.
Key Outcomes: Project was completed and cracked welds were replaced.
Drawings & Pictures:
Figure 1: Working on a section of pipe.
2 fitters working each end.
Figure 2: Some of the removed pipe
pieces staged for disposal.

3. Kevin Brock, PE, PMP – Mechanical Engineer & Project Manager kevin.b.brock@gmail.com
Limestone Handling Project
Role: Project Manager (assigned at construction mobilization)
Responsibilities: Installation & construction management personnel oversight; stakeholder engagement;
project closeout & documentation.
Scope: The scope of this project generally included adding: an emergency reclaim feeder/breaker
(frozen lump cracker); a 500 foot reclaim conveyor w/mag separator; rail unloading hoppers
and belt feeders; stockpile pile dischargers; and, diverter gates.
Background
and Conditions
Limestone delivered by truck and rail is stocked out to a stockpile. Stone is reclaimed with the
pile dischargers which feed parallel conveyors that move the store to the lime prep building
where it is further processed for use in the scrubbers. Plant operation rules require the
scrubbers be in service anytime the generating units are operating.
Statement of
Problem/Opportunity
The limestone reclaim equipment was original to the plant and had degraded over 35 years of
operation. The limestone the plant was receiving had changed from the original design
specification and the system was experiencing plugging and issues related to handling stone in
the cold (freezing stone and flash freezing in chutes and other equipment).
Key Outcomes: Project was completed under budget providing a reliable system exceeding requirements.
Drawings & Pictures:
Figure 1: New 500’ conveyor and gallery, with emergency reclaim feeder/breaker at lower left (orange)
Figure 2: New emergency reclaim feeder/breaker Figure 3: Installation of one of the new pile dischargers

4. Kevin Brock, PE, PMP – Mechanical Engineer & Project Manager kevin.b.brock@gmail.com
Crusher House Retrofit & Dust Mitigation
Role: Project Manager
Responsibilities: Project justification and charter development; stakeholder engagement, engineering services
selection; contractor/equipment selection; installation & construction management personnel
oversight; project closeout & documentation.
Scope: Replace head boxes, reline surge bin, replace dynamic vibratory feeders with brute force
vibratory feeders, replace ring-hammer mills with double roll crushers; replace alloy lined
chute with ceramic lined low-dust chute and spoon; replace and extend load zone, install
chemical dust suppression/wet flow promoter/deicing system.
Background
and Conditions
Coal is reclaimed from the yard hoppers and conveyed to a bin in the Crusher House by a
parallel conveyor system. The bin has dual outlets and each is equipped with a slide gate, a
72” wide vibrating grizzly feeder, and a ring hammer mill. The mills discharge to a chute
system with crossover that charges 36” wide conveyors “A” & “B”. The mills, feeders, chutes,
and load zones are obsolete, were designed for +4” Feed, and have been a source of dust. The
Crusher House is classified as Class II, Div II, Group F area.
Statement of
Problem/Opportunity
The Crusher House equipment has been in service for over 35 years and has processed over 80
million tons of coal. Maintenance costs have been increasing and OEM support (parts) is
decreasing. The Crusher House flow capacity is lower than the rest of the coal handling
system. The Crusher House has been identified as a high priority area for new capital
equipment to meet the OSHA national emphasis program for combustible dust.
Key Outcomes: Project was completed under budget providing a reliable system exceeding requirements
Drawings & Pictures:
Figure 1: Original Crusher House equipment Figure 2: Revised Crusher House equipment