Fort Carson Central HTHW Plant Upgrade

The first phase involved a comprehensive study to assess the condition of the HTHW Generators and auxiliary equipment. The assessment results recommended:

• Replacement of Generator (G-2)
• Replacement of the HTHW distribution pumps
• Upgrading the plant-wide controls to a distributed control system

The second phase involved upgrading plant-wide controls with dedicated combustion controls and burner management system panels installed on Generators (G-1 & G-3) along with a balance of plant control panel. Key installations:

• Microprocessor-based PLC controllers with Windows-based operating system
• Human Machine Interfaces (HMI) with touchscreen at each control panel
• Control room computer with 24" and 46" monitors
• Ultrasonic flow and energy meters on HTHW return mains
• Gas and oil flow meters on each generator to monitor efficiency
• Electric valve actuators on HTHW supply and return mains
• Triple offset rotary valves replacing gate and globe valves
• Variable frequency drive on forced draft combustion air fan for Generator (G-1)

Phase 2 Construction Cost: $1,200,000

The third phase involved replacement of a 40MMBTUH Generator (G-2) and installation of advanced equipment:

• Flue gas economizer achieving ~85% efficiency
• Replacement of forced draft combustion air fan
• Replacement of atomization air blower
• Replacement of all four (4) HTHW distribution pumps
• Installation of economizer pumps
• New pumps equipped with air-cooled seal flush cooling systems
• Variable frequency drives on new fans and pumps
• Extensive piping modifications for new equipment and flow meters
• Pipe stress analysis performed on entire HTHW system per ASME code requirements
• New combustion control and burner management system panel
• Vortex shedding flow meter on HTHW return to measure capacity and efficiency

Phase 3 Construction Cost: $2,800,000

Total Project Cost: $4,000,000