Cogen Upgrade Project

Project Scope of Work Included:

• Demolition and Replacement of Combustion Generator Foundation Slab & Auxiliary Housekeeping Pads
• Removal & Replacement of Steel Support Structures for Filter Houses Below and Above the Roof Line, Replacement of Lubricant Oil Cooler Structures
• Extensive Roofing Work to Allow for New Piping, Steel, & Electrical Work to be Completed
• Removal and Replacement of Ducting, Bypass Stacks, High-Temperature Hot Water Code Piping, High/Low-Pressure Gas Piping, Generator Lube Oil Piping, & Miscellaneous Piping Systems for Air, CO2, Non-Potable Water, and Fuel oil
• Demolition & Replacement of (3) 4.7-MW Turbines Generators with New 5.7-MW Turbine Generators and New Hot Water Heat Recovery Generators Controls
• Installation of New Variable Speed Drive for Motor within the New Turbine Generators
• Demolition of Existing Balance of Plant Control & Installation of new, Balance of Plant Control, Instrumentation, and Communications Systems
• Demolition & Replacement of (3) Control Centers with New Control System Capabilities
• Installation of (3) Continuous Emission Monitoring Systems like Mechanical Installations of New Sample Tubing From Each Stack
• Demolition & Replacement of Uninterrupted Power Supply Systems (UPS)
• Over 50,000 Feet of Control Cabling & 20,000 Feet of Power Cabling Installations with Associated Conduit

Challenges and Results

This project came with significant challenges, such as installing several pieces of large equipment over 55,000 lbs. The key to the project’s success included careful planning and logistics, a gantry system used for safe removal, and close communication between plant staff to ensure efficiency. Executed during the COVID-19 pandemic, challenges included tight working spaces, special PPE, and social distancing.