CLIENT PROFILE
The client is a global provider of specialty food ingredients and solutions.
SCOPE OF PROJECT
Our group was selected to perform preliminary and detailed engineering for a Cogeneration Project at the client’s Midwest plant.
This was a high visibility project for this international supplier of food and beverage ingredients, both globally and within the location of the facility. The project addressed their corporate environmental mission to decrease their carbon footprint and reduce greenhouse emissions. The new natural gas-fired combined heat and power system will significantly improve energy and operational efficiency at the plant.
Our team of electrical engineers reviewed the proposed layouts, configurations, intertie points of connection and the client’s ability to support the proposed 50MW load via leveraging of substation transmission and distribution feeder infrastructure.
Scope of Services Provided
Our scope included development of the documents necessary to construct and install all required equipment, piping, instrumentation, and facility modifications. The project included two new, nominal 25 MW gas turbines with fired HRSGs plus compressor packages. The two turbines and associated equipment will be integrated into the existing plant utility infrastructure.
Additional services included cost estimating, scheduling inclusive of the construction phase
Challenges Faced
We developed a FEL3 Preliminary Engineering package to support the generation of a funding grade Cost Estimate for the Plant to present to the company’s Board of Directors to gain funding approval for the project. The Project faced several challenges including a delayed start, which compressed the FEL3 phase schedule and several late scope additions required by the client. The team executed the work by rigorously following an accelerated project schedule, completing key plant visits to finalize scope and extract knowledge/data, and by responding swiftly to the client’s late scope changes by sending a “tiger team” to the site to confirm scope specifics and extract key client data plus norms. This integrated and reactive approach led to a successful execution during the FEL3 phase and ultimately the award of the detailed engineering scope following the project funding approval by the client’s Board.
Results
For this Major Project our team assembled a group of Power Generation experts that worked with a number of project partners including a Gas Turbine Generator supplier, a Heat Recovery Steam Generator (HRSG) supplier, and other mechanical equipment vendors to gain approximate footprints and budgetary pricing for the cost estimate. The team also liaised with both the Gas and Electrical Utility Suppliers plus the client’s site Electrical Engineering and Geotechnical contractor to generator the preliminary engineering design documents.
Our experts utilized Thermoflex software to develop a heat and material balance to specify and size key equipment and piping. A preliminary 3D model was generated to define the layout of new structures and equipment within the existing plant.