HomeMy WebLinkAbout19970312 Project Update SPECJRO
ALLOYS CORP
13220 Doyle Path
Rosemount, MN 55068 U.S.A.
FAX: 612/438 -3714
Phone: 612/437 -2815
March 12, 1997
City of Rosemount
Planning Department
2875 145th Street West
Box 510
Rosemount, MN 55061; -0510
ATTENTION: Mr. F.ichard Pearson, Assistant Planner
SUBJECT: PROJECT UPDATE COPIES
Dear Sir:
Enclosed are two (2) copies of the PROJECT UPDATE that was presented to the City of
Rosemount on March 1997 by Mr. Dan Hoklas. These documents were meant as an
introduction summary of the projects and does not contain specific dimensions or ratings. More
detailed information will be available to you by the 28th of this month.
We are currently brainstorming on the issues of concern with the Department of Natural
Resources (D.N.R.) and we hope to have an action plan by the end of next week (March 21,
1997). When we have a viable plan ready, we will contact your office and set up a time to
present the plan to you and your colleagues.
If you have any questions for our office or if there is anything else I can do for you, please don't
hesitate to call or fax. Thank you for your patience and cooperation in this matter.
Sincerely,
Mark Schuler
Maintenance Coordinator
13220 Doyle Path, Rosemount, MN 55608
SPECTRO ALLOYS CORPORATION
SPECIAL
NOTICE:
Enclosed is a copy of the PROJECT UPDATE that was presented to the
City of Rosemount on March 3, 1997 by Mr. Dan Hoklas. These
documents were meant as an introduction summary of the projects and
does not contain specific dimensions or ratings. More detailed
information will be available by March 28, 1997.
We are currently brainstorming on the issues concerning plant aesthetics
and beautification and we hope to have an action plan by the end of the
month. When we have a viable plan ready, we will be more than happy
to present the plan to you and your colleagues.
13220 Doyle Path Rosemount, MN 55068
PROJECT UPDATE
PLANS FOR 1997 AND 1998
SPECTRO ALLOYS CORP.
13220 DOYLE PATH EAST,
ROSEMOUNT, MN 55068
SPECTRO ALLOYS CORPORATION
City of Rosemount Briefing
21 February 1997
TABLE of CONTENTS
Preface 1
Layout 2
Part 1 (Shredder Plant) 3
Part 2 (Fire and Safety) 6
Part 3 (Oxygen System) 9
Part 4 (MCC) 11
Part 5 (5 Bin Storage) 13
App. A (Shredder Plant) 14
App. B (Fire and Safety) 16
App. C (Oxygen System) 26
App. D (MCC) 29
App. E (5 Bin Storage) 32
13220 Doyle Path Rosemount, MN 55068
SPECTRO ALLOYS CORPORATION
PREFACE
Spectro Alloys Corporation has been a part of the Rosemount industrial
complex for close to 25 years. We have a history that is rich in diversity
and we are proud of the progress we have made from humble beginnings.
We have driven ourselves to become an industry leader and we feel very
confident that we can continue to be a leader in the years to come.
We are pleased to be part of the Southern Metro and we want to do what is
best for our community. The purpose of the meeting is to share
information with the City of Rosemount and to discuss future plans for
Spectro Alloys.
We have made significant strides in the improvement of the plant and we
are very excited about our vision for the future. The projects we would
like to discuss at this meeting are new shredding plant, the fire and safety
alarms system, the new oxygen generating system, the new motor control
center expansion and the 5 -bin storage system. The information contained
in this document is not meant to be all inclusive and complete, rather it is
intended to be a basis for futher communication between Spectro Alloys
and the City of Rosemount.
13220 Doyle Path Rosemount, MN 55068 612 437 -2815
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;7SPEOTRO ALLOYS CORPORATION 98 February 1997
Part 9
il_ �1 I G Ott h t E
Pro,osal
SUMMARY
In order to decrease the raw material inventory, to minimize the electrical power con-
sumption, to improve the safety of the workers and to enhance the environmental
friendliness of the plant, Spectro Alloys is proposing the replacement of the material
shredding system.
PURPOSE
Our resent two-stage shredding system is worn out and is becoming increasingly
p 9 9 Y 9 9Y
costly to operate. The proposed replacement system is safer to operate, eliminates the
need for a second stage and can be operated for shorter periods of time. This system
can also be installed with no down time to the existing system.
INVENTORY MANAGEMENT
The proposed shredding system produces material with a greater density than our cur-
rent system which results in several benefits.
Because the density can be increased and the throughput is greater, we can store
more processed material in Tess space. This allows us to process a greater percentage
of our scrap. The material that has been processed can also be more efficiently man-
aged which will reduce the possibility of cross contamination of the alloy types.
The new system would also allow us to process customer emergency orders because
raw materials can be processed as it arrives. That ability will allow us to reduce the
ground space occupied by raw material awaiting processing. This also has the affect
of clearing passageways in the plant that is currently taken up by raw material
inventory.
ELECTRICAL CONSUMPTION
The proposed shredding system can be operated less often than our existing system to
produce the same amount. This works to our advantage and to the surrounding area
by allowing Spectro Alloys to operate the system on "Off Peak" hours (9:00 p.m. to 9:00
a.m.; Monday through Friday). This should have a tremendous impact during the sum-
mer months when the overall electrical load on the grid is very high during the day. In
fact, by switching to the new system, we expect to reduce our electrical consumption by
165,000 kilowatt -hours per year.
An added bonus to the proposed system is that modem switchgear is much more effi-
cient than what we are presently using. This means that there will also be less of an
effect on the surrounding area when electrical Toads are started or stopped. This will
help to reduce the annoying condition referred to as "brown out" (which has been know
to disrupt electronic equipment).
WORKER SAFETY
Our present system is very labor intensive, heavy and dangerous. The configuration of
the machine makes it very difficult to provide workers with convenient equipment. The
present system uses sharp knives which creates a potential handling problem to work-
ers. In addition, the electrical switchgear is field mounted and poses a threat to work-
ers who may come in contact with these devices.
The proposed system will have maintenance equipment designed with the worker in
mind. This places the worker in a much safer environment and reduces the chance of
out -of- position lifting. Hydraulic maintenance equipment is designed into the system to
eliminate the need for the classic pry-bars and sledgehammers. Since there are no
knives in the proposed system and because special transport gear is designed into the
system, the chance of injury during equipment handling is reduced.
An added feature of operating the system for less time during the week is the reduction
in stress to the maintenance staff. The employees will feel less stress to make a tight
deadline and foolish mistakes can be greatly reduced. This also allows for a compre-
hensive "post project" inspection of the system prior to returning it to operation.
z
ENVIRONMENTAL IMPACT
One of the most appealing aspects of the proposed system is the impact the change
will have on the environment. The proposed system is more efficient, improves the
cleanliness of the furnaces, reduces emissions and enhances the plant's ability to deal
with storm water runoff.
Because the system is more efficient, we will use less electricity and we can operate
the plant for fewer hours per day. The efficiency increase means we conserve energy
also allows us to process material only as it is needed.
The proposed system separates dirt from the raw material better and the dirt and "fi-
nes" are segregated for proper disposal. Because the system has this capability, it al-
lows us to process cleaner scrap material for our furnaces. This in turn reduces the
emissions of the furnaces and, by virtue of the increase in density, decreases the
amount of oxides that are produced in the furnaces.
The proposed system will utilize a baghouse dust collection system to prevent any fugi-
tive dust or vapors from escaping the shredding plant. The dust collector will also han-
dle any fugitive dust generated along the material conveying system.
The immediate benefit of the proposed system will be in the decrease in plant ground
space. This means that less raw material will be in storage on plant grounds and re-
duces the impact our scrap has on storm water runoff. In fact, we will be utilizing just-
in-time (JIT) management practices so that there will be very little raw inventory on
sight at all. Our goal is to eventually have all the scrap in covered bins.
CONCLUSIONS
The installation of the proposed system will provide an increase in reliability, an in-
crease in worker safety, a decrease in raw material inventory, a decrease in electrical
consumption and a decrease in plant air emissions.
All the new systems will be the latest technology and will be the most efficient equip-
ment available. The vendors are all industry leaders and the professionals assigned to
the project are extremely capable and are highly respected by their peers,
SPECTRO AL L OYS C 18 February 1997
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Part 2
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F and Saf
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SUMMARY
Significant safety systems at Spectro Alloys have been enhanced or modified to pro-
vide greater protection for the workers and the surrounding community. These systems
include the chlorine detection system, the fire alarm system, the emergency lighting
system and the plant voice alarm system.
PURPOSE
1
To provide an early warning system of plant emergencies to all plant personnel and to
assist in the proper response for the emergency.
CHLORINE SAFETY SYSTEM
The chlorine safety system has been improved to provide a greater degree of early
warning and to provide and automatic leak isolation feature for the majority of the sup-
ply system. A diagram of the system can be found in appendix B.
Two chlorine gas detectors have been installed at each furnace distribution manifold.
They sound a plant wide voice alarm if either unit detects gas levels in excess of preset
levels. In addition to the voice alarm, these detectors will energize a circuit which auto-
matically closes the main supply valve for that furnace in the main control room
(effectively isolating the leak without human intervention).
Another gas detector has been added in our remote chlorine gas building which sup-
plies small amounts of gas to the furnace support equipment. This detector, like the
unit in the main control room, sounds the plant voice alarm and calls for the Emergnecy
Response Team for intervention.
illP
6
In the main chlorine control room, a safety circuit has been installed that involves sev-
eral interlocks before a bank of tanks can be moved.... either in or out. This interlock
circuit must have the following conditions in order to be satisfied: the overhead door
for that bank must be open, the main manifold supply valve must be closed and the op-
posite bank's drive box must be closed and latched. This prevents a bank from being
moved while it is still in use.
In the near future, we would like to upgrade the present system with a bulk chlorine
system. This would have the effect of reducing the number of potential leak sights by a
factor of 20. It also decreases the frequency with which workers must interface with
the system, thus reducing the chance of a release accident.
FIRE ALARM SYSTEM
We have identified the need for a plant fire and emergency alarm system to augment
our present alarms system. We have designed the system to integrate with a new
voice alarm system to warn employees of a plant fire or a medical emergency.
This system consists of eight (8) manually activated fire alarms placed strategically
throughout the plant (see App. B). Alarm horns will sound in three (3) different sections
of the plant to alert all plant and non -plant personnel of an emergency. The horns are
followed by voice alarms to verify the alarm condition. This system has the capability
of being tied in with an AUTO DIALER if so desired.
The alarms may be activated by anyone who discovers the emergency sitution and it
provides a means of alerting foreman and supervisors in the event of a medical emer-
gency as well as a fire. Personnel training will be conducted on the proper response
techniques in an emergency situation.
Supervisory personnel in the main Production office will have an alarm indicator panel
mounted in plain sight. This panel will have indicator lights to allow them to know the
location of the emergency remotely. They will be expected to start conducting opera-
tions from a remote spot in order to save valuable time. A copy of the control circuit
schematic is provided in appendix B.
EMERGENCY LIGHTING SYSTEM
In conjunction with the new fire and emergency alarm system, we have upgraded our
emergency lighting system. The purpose was to ensure that all lighted exit signs have
sealed beam lamps, that all blind corners of the operating spaces have an emergency
Tight illuminating the dangerously dark areas and that specific exterior areas have
"harsh environment" emergency lights to illuminate remote operating areas of the plant.
These are areas where workers may be isolated in an emergency from other workers
or rescue teams and these exterior lights would also prove beneficial while personnel
are combatting a casualty. A diagram showing lighting locations may be found in ap-
pendix B.
We also have emergency lighting in all our areas near the furnaces. This allows work-
ers to place the furnaces in a safe condition should they have to evacuate the area
without main power. In addition to the generic emergency lighting equipment, we have
special emergency lighting equipment installed to provide lighting for our molten metal
handling gear. This equipment allows us to use a gas powered, portable welder to pro-
vide 120 vac power to some lighting fixtures.
PLANT VOICE ALARM SYSTEM
We are installing a new voice alarm system which is much more flexible than our pres-
ent system. The new system will allow us to tie in our other alarm systems and is also
allows us to prioritize alarms. In this way, we can ensure that the most life threatening
or most damaging alarms are never "over- ridden" by other incoming alarms.
We have an unlimited capacity for expansion in this system and new alarms can be
easily added by a special recording interface box. Alarms may be modified, priorities
may be changed and new alarms added at any time. The alarm system can be pro-
tected by passwords or by physical means (keys) to prevent tampering and there are
several input and output options available.
8
SPPCTRO ALLOYS CORPORATION 18 February 1997
Part 3
O xygen System
P
SUMMARY
Spectro Alloys is currently testing an oxygen combustion burner system to determine
the feasibility and the profitability of use with an Aluminum smelting furnace. If the re-
sults are satisfactory we would like to install an oxygen generating plant and a liquid
oxygen storage center.
PURPOSE
To provide an increase in system efficiency, to reduce the natural gas usage at the fur-
nace combustion system and to decrease the NO emissions.
EFFICIENCY
The furnaces that we use are large frame, natural gas fired burners. They provide ade-
quate heat input but use a large quantity of natural gas and not very efficient. The pro-
posed burner system replaces the air used in our burners (nitrogen, argon, oxygen,
etc.) with pure oxygen which results in higher efficiency.
The burners in particular are more efficient because they are designed to produce a
wide, flat flame (as opposed to the shape of an jet aircraft's exhaust). The oxygen
burners transfer the majority of the heat by radiant energy instead of convective ener-
gy. Because oxygen is a combustion enhancer, the temperature of the flame is much
higher and it transfers the heat better. This increase in the heat transfer rate allows
the burner to be much smaller and also allows it to require much less fuel.
41
FUEL SAVINGS
Because the burners are smaller and more efficient, less fuel is need to produce the
same heating effect. The result of this is an estimated 40% reduction in fuel usage.
Projected out over a year that figure represents a reduction of over 438 billion BTU's
(that's roughly equivalent to running 270 household furnaces at full capacity for an en-
tire year).
LOWERED FURNACE EMISSIONS
In the proposed oxygen system, the furnaces are no longer supplied all the inert and
non useful gases to the combustion chamber, so the emissions from the furnace will be
reduced. This is in addition to the fact that the overall volume of combustion gases are
reduced to the decrease in size of the burners.
The reduction in all the non useful gases also has an affect on the life of the furnace.
The furnace does not have to heat all the inert gases and subsequently the walls and
ceiling of the furnace, so the furnace has a longer life expectancy. This inevitably
means that there is less material demolished and sent to the landfills as a result of fur-
nace rebuild projects.
41
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SPECTRO ALLOYS CORPORATION 18 February 1997
-s F- :i.: 1 -Y.. zii ..-.7.:
Part 4
E x pan s i o n
P
SUMMARY
We are proposing an expansion and upgrade to our existing Building #4 Motor Control
Center. The new expansion would incorporate a crawl space under the main floor for
ease of troubleshooting and electrical installation. The new switchgear which is
planned for the installation, will be the latest generation design which is more efficient
and more reliable. This new equipment will replace gear that is inefficient and poten-
tially dangerous to workers.
BUILDING CHANGES
The actual enclosure for the proposed MCC will be modified by adding an additional 15
feet of space extending southward. The construction materials will be designed to
meet all code requirements and will have a crawl space for access to electrical panels.
The flooring in the new section will be steel decking.
A drawing of the proposed expansion is enclosed for review (see App. D). Specific de-
tails of the construction of this expansion will be available as the design is refined.
Jack Lewison will be the point of contact for Spectro Alloys.
ELECTRICAL CHANGES
The new switchgear will be simple motor control devices. The latest generation of
equipment uses solid -state controls to monitor load conditions and this design is supe-
rior in performance to the old "heaters" and mechanical overloads presently employed.
The new gear is also more energy efficient than our present gear which will equate to
an additional energy savings.
1
The greatest advantage of the new switchgear however is the improvement in worker
safety and fire prevention. The new expansion calls for the installation of another sup-
ply disconnect. This has the benefit of allowing us to isolate all power to the north half
of the plant from one location in the event of an electrical fire.
Another advantage of the new system is that all the new switchgear will operate at low-
er temperatures than our present equipment. Less heat Toad on the MCC building will
mean Tess chance of equipment malfunction and Tess chance of a building fire.
1
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SP A CORPORATION 18 February 1997
6
Part 5
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SUMMARY
A heavy construction, covered concrete storage system is being proposed as a new
storage area for our "turnings" scrap material. This system would allow greater scrap
integrity, reduce the amount of raw material stored on the ground (Storm Water Act
compliance) and improve the plant's inventory management ability.
LOCATION
III
The proposed system will be located along the south wall of building #4. The location
was determined by the need for incoming trucks to be able to dump Toads into the bins
and by the proximity to the processing plant.
This structure would share its north wall with the south wall of building #4, and the east
end bin would share part of its wall with the new MCC. The west bin wall would ex-
tend all the way to the end of building #4.
DESIGN and FUNCTION
The bins are designed as a concrete and steel composite that is strong enough to sup-
port front loader work inside the enclosure. Reinforcements will be cast in to the lower
portions of the walls. Steel framing extends from about fourteen (14) feet up to the roof
and a steel panel exterior is bolted to the framing to enclose the bins.
The bins will hold scrap material waiting to be processed. This material is generally
"turnings" which are best described as aluminum shavings similar to what might be
found at a machine shop. This material due to the nature of its origin often has oil or
cutting fluid on it. The covered roof and walls of the new storage system would prevent
any contaminants from reaching the soil because the walls act as a "sump" of sorts.
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To: SAFETY AND TRAINING COORDINATOR
From: Mark Schuler
Date: 19 July 1996
Subject: PLANT ALARM SYSTEM UPGRADE
Jim,
The following is a new list of the plant alarms which will be effective by the middle of
September. The new alarms reflect the plant equipment changes made already to the
plant:
1. Chlorine Emergency.... Evacuate the Plant
2. Chlorine Emergency...Man Down, Requires Rescue
3. Chlorine Emergency...Leak in the Control Room....Response
Team Needed.
4. Chlorine Emergency.... Leak in the Degas Building...Response
Team Needed.
5. Chlorine Emergency.... Leak at Furnace One...System Isolated
Maintenance Investigate.
6. Chlorine Emergency.... Leak at Furnace Three System Isolated
Maintenance Investigate.
7. Chlorine Waming....High Pressure Indicated Maintenance
Investigate.
8. Chlorine Warning....System Depleted....Switch to Other Bank.
9. Dryer System...Man Down, Investigate all Conveyors.
I�.
10. Dryer Elevator Jammed.... Operator Respond.
11. Weather Hazard Approaching Seek Shelter.
Indicates changes made to plant systems or new equipment
installed.
Mark Schuler
Maintenance Coordinator
SPECTRO ALLOYS CORP.
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ALARM INDICATOR PANEL
#1. Building #4
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It #8 Bldg. #4 MCC
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13220 Doyle Path Rosemount, MN 55068
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1 J12 LABORATORY, OFFICE SHOWER ROOM
2 M 7 SPECTRO ALLOYS OFFICE
3 0 9 BUILDING #1, FURNACE #1
4 0 12 BUILDING #2, WAREHOUSE
5 H 11 Nag WAREHOUSE
6 H 7 ENGINEERING OFFICE LUNCH ROOM
7 K 15 TURNINGS PROCESSING BUILDING
8 H 14 MAINTENANCE SHOP OFFICE
41" 9 E 20 BUILDING #4, FURNACE #3
10 I 22.5 CHLORINE STORAGE BUILDING
11 H 23 SODIUM STORAGE SHED
12 B 13
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13 J 22.5 NITROGEN TANK
14 E 12 BAGHOUSE LIME SILO
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16 N 14 SHREDDING PLANT
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