Golden Cogeneration Power Plant

Golden, Colorado

GDF SUEZ North America had plans to complete a blended fuels project for one of the main boilers at their Golden, Colorado power plant (primarily serving the Molson-Coors Brewery).  The boiler was being fueled by coal, but the plan was to convert it to natural gas, or a combination of the two fuels.

Behrent developed a $3.5 million budget for the project. When the preliminary engineering package was ready, EPC bidders were invited to a pre-bid meeting and project walk, and were also given a chance to individually present their bids to the evaluation team.

Because of Behrent’s involvement in the preliminary engineering phase and familiarity with the project requirements, plant management then retained Behrent Engineering to execute the detailed engineering phase of the project. 

Behrent was also asked to develop detailed subcontractor bid packages and assisted in the bid evaluation process.

Project Summary

The project had three main objectives:

  • Install natural gas piping.
  • Replace flame safety controls (Norpak panel).
  • Replace combustion controls (Fisher AC3).

To accomplish those objectives, the project included the following scope of work:

  • Install the new flame safety control panel near the Norpak panel. Use redundant Rockwell Automation Control Logix 1756-L72 PLCs for the new panel. Plan to convert the Norpak panel to a marshaling cabinet. Save and reuse all field instrumentation and wiring.
  • During shutdown: Cut over to new flame safety controls. Replace half of the pulverized coal fuel nozzles. Inspect the condition of existing gas fuel nozzles.
  • Install a new 10-inch gas main to Boiler 5, including main gas stop valve, flow, and pressure controls; block and bleed valves to each gas burner; and combustible gas detectors.
  • Hot tap the existing main gas header while the boilers continued in operation.
  • Install the new combustion control PLC system near the Fisher AC3 racks. Use Rockwell Automation ControlLogix 1756- L72 PLC. Add marshaling terminal blocks to existing Fisher AC3 racks. Prewire the new PLC to marshaling terminal blocks. Save and reuse all existing field instrumentation and wiring.
  • Connect all new gas line valves and instrumentation to the new PLC panels.
  • Update the iFIX SCADA system to include the new gas line valves and instrumentation and to interface and gather data from the new PLCs.
  • During winter shutdown: Cut over to new combustion controls. Replace Fisher AC3 operator stations with new Rockwell Automation PanelView Plus 6 15-inch color touch screens. Tie in new gas line to each existing gas nozzle. Replace remaining pulverized coal fuel nozzles.
  • Develop detailed checklists for panel checkout and software testing.

Fuel Flexibility.

Fuel flexibility was a primary driver of this project, and Boiler 5 is now capable of firing the following fuel combinations and percentages:

  • 100% coal (from western Colorado, primarily bituminous)
  • 100% natural gas (from Xcel Energy)
  • 50% to 100% coal, blended with natural gas

Project Cost and Schedule.

Due to the detailed planning and coordination used on this project, the project was completed on time and approximately 10% under budget.

Ultimately, this project was awarded Power Magazines “2015 Reinvention Award” (formerly known as the Marmaduke Award).

McPherson Melter Project

McPherson, Kansas

Behrent Engineering was contracted to provide the engineering services necessary to replace one of three existing power supplies serving three glass melters at a manufacturing facility in McPherson, Kansas.

Behrent Engineering provided the engineering and design services as follows:

Electrical

  • Assembled electrical demolition package for the removal of the existing Robicon SCR Power Supply as well as the Melter Electrode Copper Bus and locomotive cables.
  • Prepared plant 1-line diagrams
  • Prepared plant electrical SKM software model
  • Provided an Arc-Flash study
  • Produced Time-Current Coordination (TCC) curves for protective devices
  • Provided revised electrical plan drawings.

Structural

  • Evaluated existing steel structure for final placement of Varivolt transformer and MV contactor
  • Evaluated existing steel structure to design a transport path for the Varivolt transformer.
  • Developed structural scope of work for removal of existing Robicon SCR Power Supply Unit.
  • Designed secondary containment area and fenced enclosure for new Varivolt transformer.
  • Analyzed existing structure and designed new cable tray supports.

Innisfail Scrubber Stack Project

Alberta, Canada

Behrent Engineering was contracted to provide engineering, procurement, construction, startup & commissioning, and management for abatement equipment used to reduce fibrous emissions from the HERM manufacturing line collection stacks at a manufacturing facility in Innisfail, Alberta, Canada.

The project was designed to have three low energy type wet scrubbers (one per Module) to control particulate emissions, including a complete process scrubber water system. General arrangement drawings were developed to show the final equipment arrangement. 

The project scope was divided into three primary areas:

  • Demolition
  • Abatement / Process Air System
  • Process / Scrubber Water System

Behrent Engineering developed the process flow diagrams, piping and instrumentation diagrams for the new process water system and scrubber system.

Behrent also developed the equipment and piping drawings for a complete and operable water system.

  • Foundations
  • Scrubbers
  • Fans
  • Pumps
  • Tanks
  • Process water pits
  • Trenches
  • Area floor slab
  • Pads for MCC’s, equipment, etc
  • Equipment platform slabs
  • Structural Steel
  • Access platforms
  • Stairs
  • Existing roof steel modifications
  • Pipe supports
  • Equipment monorails

Behrent Engineering also provided the electrical design and drawings for the 575 volt and 4160 volt distribution and single-lines, 575 schematics, grounding, lighting, power, cable tray routing and electrical installation plans.

Louisville CEMS & DAHS Design

Louisville, Kentucky

In order to comply with new federal regulations regarding allowable emissions at cement plants, our client was required to install Continuous Emission Monitoring Systems (CEMS) and Data Acquisition and Handling Systems (DAHS) at eleven of their cement manufacturing facilities across the United States.

Behrent Engineering provided the required engineering design and development of the bid packages to submit to third party contractors for the installation of the CEMS & DAHS systems.

Site visits were conducted by lead members of Behrent’s project team to gather field information and help to determine the location of the CEMS building and cable tray routing.

Structural steel drawings were prepared for the construction of the required stack platforms, stack monorails and cable tray supports. Air piping, electrical conduit, fiber optic cable, stack ports and special emissions monitoring equipment were also engineered and detailed on the plans.

Brooksville Cement Plant

Brooksville, Florida

In order to comply with new federal regulations regarding allowable emissions at cement plants, our client was required to install Continuous Emission Monitoring Systems (CEMS) and Data Acquisition and Handling Systems (DAHS) at eleven of their cement manufacturing facilities across the United States.

Behrent Engineering provided the required engineering design and development of the bid packages to submit to third party contractors for the installation of the CEMS & DAHS systems.

Structural steel drawings were prepared for the construction of the required stack platforms, stack monorails and cable tray supports.

Boulder Pharmaceutical Project

Boulder, Colorado

Behrent Engineering was contracted by a pharmaceutical company located in Boulder, Colorado to engineer a dust collection system for their facility.

Behrent provided the engineering and design services for the following tasks:

  • Analyzed, tested and measured the existing hood and checked clearances to nearby pressure indicating gauges and other equipment.
  • Designed, modeled and CFD analyzed a new dust collection hood per ANSI Z9.2 standards.
  • Created fabrication GA drawings for use in fabricating the new hood.
  • Provided assistance in hood fit-up and fabrication support.
  • Performed necessary testing during and after the installation.

Clinchfield Emissions Monitoring

Clinchfield, Georgia

In order to comply with new federal regulations regarding allowable emissions at cement plants, our client was required to install Continuous Emission Monitoring Systems (CEMS) and Data Acquisition and Handling Systems (DAHS) at eleven of their cement manufacturing facilities across the United States.

Behrent Engineering provided the required engineering design and development of the bid packages to submit to third party contractors for the installation of the CEMS & DAHS systems.

Site visits were conducted by lead members of Behrent’s project team to gather field information and help to determine the location of the CEMS building and cable tray routing. General arrangement drawings were prepared to show the overall location of the CEMS building, the emission stacks, stack platforms, cable tray routing and overall site dimensions.

Structural steel drawings were prepared for the construction of the required stack platforms, stack monorails and cable tray supports. Air piping, electrical conduit, fiber optic cable, stack ports and special emissions monitoring equipment were also engineered and detailed on the plans.

Rifle Sodium Bicarbonate Plant

Rifle, Colorado

In anticipation of a sodium bicarbonate plant expansion in Rifle, Colorado, Beherent Engineering was contracted to upgrade the existing plant boiler capacity. The plant had one CB7002200 boiler for train #2 and two CB100800 boilers for train #1

The project was constructed in two phases. The first phase was the installation of the boiler in the open space between train #2 boiler and the two boilers for train #1. After the completion of the first phase, the second phase of construction was started.

The second phase was the demolition of the two existing boilers for train #1, demolition of the building and foundations for the two train #1 boilers, the construction of new concrete foundations for the new train #1 boiler/building enclosure and the erection of a new building enclosure over train #1 boiler and the boiler in the open space between train #1 boiler and train #2 boiler. 

Behrent provided the engineering and design services for the following tasks:

  • 3D laser scanning was performed to develop an AutoCAD 3D model of the work area.
  • Developed conceptual layouts to determine the location of train #3 boiler for client approval.
  • Developed conceptual layouts for the new boiler for train #1, showing location of boiler, access and new building enclosure around train #1 and train #3 boilers for client approval.
  • Provided a preliminary update of the P&ID for the addition of the new boilers.
  • Determined steam piping changes/modifications necessary for the addition of train #3 boiler and train #1 boiler
  • Provided preliminary updates of existing electrical single lines for new boiler loads
  • Prepared Final Engineering scope of work

Golden Brewery Project

Golden, Colorado

Behrent Engineering was contracted to provide the engineering and design services required to decommission the ammonia portion of the Chiller in the Prime Beer system at the Golden, Colorado brewery. This project included capping the ammonia liquid, vapor, oil pot bypass, and relief lines, as well as capping the beer lines.  Behrent provided the engineering and design for the following tasks:

  • Confirmed the scope of the demolition and capping locations on the P&ID and in the field with operations.
  • Defined & confirmed sanitary decommissioning of beer lines
  • Provided piping drawings for demolition and photo drawings/sketches.
  • Provided piping drawings for capping and photo drawings/sketches.
  • Provided demolition and piping construction scope of work.
  • Provided isolation mapping
  • Updated the utilities P&ID and uploaded to team center.
  • Updated the utilities schematic.
  • Updated the utilities ammonia valve isolation schematic.

Marseilles Anhydrous Ammonia Terminal

Marseilles, Illinois

At the Marseilles anhydrous ammonia storage terminal it was desired to eliminate the possibility of accidental release of anhydrous ammonia to the atmosphere by protecting all tanks, vessels, equipment, and piping from overpressure scenarios, and by destroying any release of ammonia by the use of flares.

Behrent Engineering was contracted to perform a detailed study, and to make necessary recommendations for additional and/or different pressure/vacuum relief valves, hydrostatic relief valves, piping, flare headers and new flares

Behrent provided Mechanical, Electrical, and Structural Engineering to produce a Contractor IFB package including Scope of Work, 2-D piping drawings, Bill of Materials, Electrical Plans, Wiring Diagrams, Structural Plans and details for Flare modifications or new installation as required.  Final record drawing P&IDs and electrical drawings were provided after construction completion.