Fort Carson Replace HTHW Generator No. 1

SEC designed the replacement of the 55-MMBTU High Temperature Hot Water Generator No. 1 at Fort Carson, Colorado. The project included the generator replacement, flue gas economizer installation achieving approximately 85% efficiency, and comprehensive control system upgrades. Construction cost was $8,200,000, completed in November 2021.

The new generator features dual fuel capability for oil and natural gas. Supporting systems include a forced draft fan replacement, new combustion air louvers, atomization air blowers, seal flush cooling systems for four HTHW distribution pumps using API 23 pump seals with shell and tube heat exchangers. The project also included piping and valve replacements, new catwalks, roofing modifications, and MTHW converter replacements. Variable frequency drives were installed on the fan, pumps, and blower.

The control system features PLC microprocessor controllers with a Windows-based operating system, HMI touchscreen interfaces, and 46-inch monitors in the control room for comprehensive plant monitoring. Vortex shedding flow and energy meters provide precise measurement of system performance.