Lifecycle Improvements


A large national utility committed resources to be invested in the handling system of one of its Texas generating stations. The goal was  to ensure that it continue to perform well over its next phase of life.  In order to get a handle on current operations and challenges, Plant Professionals was selected as an independent resource to assess the condition of the station, and help  prioritize projects.

The station has multiple units, with independent rail unloading systems and material handling systems.  All coal is brought in by rail from the Powder River Basin, and the plant consumes several million tons per year.

Challenges to upgrading the system included limited windows to perform the upgrades, so recommendations and designs need to take this into consideration.


  • Initial P2 assessment
  • Prioritization and Plan Development, Project Management
  • Benetech Technology group and partner engineer firm developed over 20 generic, technology focused bid packages that the station used to go out to bid
  • Benetech was successful on several of the upgrades and provided Project Design, Supply, Install and management on those projects

 Lifecycle Improvements Include:

  • Multiple Transfer System Installations
  • Redesign of Crusher system
  • Washdown system
  • Dust suppression System Upgrades
  • Electronic Magnet
  • Grizzley Project
  • Scale Install

Solution Achieved

The station was able to evaluate and select several projects to improve safety and efficiency.  New projects continue to move forward on the plan developed with advice and direction from the Plant Professionals team.  The Benetech team continues to support the plant team in the successful implementation of the lifecycle upgrades to increase safe handling of PRB coal and ensure the station is ready for the next phase of its operating life.