Reducing Power Plant Emissions, Maintaining Operations

Confidential Client USA

Engineering procurement construction (EPC) delivery of two new selective catalytic reduction (SCR) systems helped one power client meet federal decrees.

EPC Delivery and SCR Systems Help Power Client Meet Federal Decrees

Faced with U.S. Environmental Protection Agency decrees, a confidential U.S. power provider in the western United States needed to identify a solution to reducing emissions to maintain its operation as a coal-fired power plant—a substantial component of the company’s energy production portfolio. To help this client meet the compliance requirements, keep its business running and continue its commitment as an environmental steward, CDM Smith, in a consortium with Babcock & Wilcox (B&W), designed and built two new selective catalytic reduction (SCR) systems and associated balance of plant equipment.

It was important to us and the client to keep the facility operating so everyone could continue working.

Joe Gidcumb, Project Manager

These facility upgrades were completed under an engineer-procure-construct (EPC) contract. The EPC approach enabled the project team to maintain continuous plant operations during construction, streamlining delivery and maintaining budget, schedule and an exemplary safety record. “This facility is a significant part of the community,” said LPG project manager Joe Gidcumb. “A lot of people are employed directly by the station or in support of its operation. It was important to us and the client to keep the facility operating so everyone could continue working.” Scheduled plant outages allowed the team to achieve significant milestones and advance the project safely, while limiting disruption to the client's employees.

Atop one of the client's power generation units, you can see structural steel being erected to support the SCR systems.

The project required the relocation of process and utility piping during short scheduled unit outages.

Construction of an induced draft fan foundations. These fans help correct pressure drops in the system by pulling flue gas generated at the facility through the system and up through the smoke stack.

Within one of the SCR systems, you can see the lower portion of the SCR hoppers and ductwork, cable tray, structural steel and other balance of plant components.

Anhydrous ammonia gets transported to the SCR systems via a pipe rack. The ammonia is used as a reagent, injected into the flue gas stream to form a reaction with the SCR catalysts and convert nitrogen oxide to nitrogen and water.

LPG provided a full range of engineering services to support the project, including laser scans of existing structures, geotechnical investigations, site surveys, permitting, architectural, civil, electrical, piping and structural engineering. Procurement services included the supply and installation of medium-voltage variable frequency drives and enclosure, pre-manufactured electrical equipment and buildings, and small and large-bore process piping and structural steel supports associated with pipe racks, cable tray, flue, and SCR support structures. Construction activities include utility relocations, SCR and equipment foundations, deep foundations featuring drilled piers and micropiles, and installation of ammonia equipment and process piping and all associated electrical components.

Now compliant with federal mandates, the facility exemplifies the client's commitment to the environment while preserving its energy portfolio and local jobs. The project also continues a 20-year working relationship between LPG and B&W, a global leader in advanced energy and environmental technologies and services for power and industrial markets.