Electric Utilities

Chouteau 2 Combined Cycle
Associated Electric Cooperative, Inc.

Sega is the owner’s engineer for the relocation and construction of a 500-MW Nominal 2-on-1 Siemens combined cycle plant. Developed and negotiated the engineer, procure and construct (EPC) power block construction contract and Sega is providing detailed design for the site preparation, water treatment, chiller retrofit and other construction packages. Sega is providing construction and start-up support.

ESP Rebuild Projects - Jeffrey Units 1 & 3; Tecumseh Unit 9
Westar Energy

The project focused on rebuilding the existing electrostatic precipitators (ESP) and adding enclosures to the top of the ESPs at Westar’s Tecumseh and Jeffrey power generation facilities. The Tecumseh project also included upgrading the ID fans and replacing the mechanical dust collectors.

Combustion Turbine Generator Facility - Orange Grove Power Plant
Orange Grove Energy and San Diego Gas & Electric

This EPC project included the site development and the installation of two 45-MW simple cycle combustion turbine generators (General Electric LM6000 PC Sprint) to a “Greenfield” site. The project included site preparation, a two-mile gas pipeline, trucked-in water supply, 69-kV underground transmission line to utility substation, foundations, maintenance building with central control room, 69-kV substation with protection and control, gas compressors, SCR, noise restrictions, and plant controls integration.

Southeast Substation
City of Ottawa, KS

Sega designed a new greenfield substation consisting of a 161-kV ring bus, a 161-12.47-kV transformer, and a 12.47-kV outdoor substation. The 161-kV substation was designed for two initial 161-kV transmission lines, a future 161-kV line, and a future transformer. The 12.47-kV substation was designed for three initial distribution feeders, with provisions for future feeders and a tie breaker to the second transformer bus. The project also included the construction of approximately three miles of new overhead distribution lines and reconductoring of several miles of existing distribution line.

Combustion Turbine Generator - Osawatomie Generating Station
KCP&L

This project is designed and developed for eight 80-MW GE gas turbine generator units located at a greenfield site. One unit was installed as part of this initial project, as well as total site grading, drainage and utilities. The project includes site preparation, detention basin design, foundations, service/control building, SCADA interface, mechanical and electrical assembly and installation, substation interface, and natural gas interface.

Substation R
Independence Power & Light

This project was a greenfield substation consisting of a 69-kV ring bus, two 69-12.47-kV transformers, two 69-kV transmission lines, and 15-kV class switchgear. The switchgear is designed for eight distribution feeders, auxiliary cubicles and a tie breaker.

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New Combustion Turbines 315-MW - South Harper Peaking Facility
KCP&L

This project was a 315-MW simple cycle peaking plant consisting of three SW501D5A natural gas-fired combustion turbine generating sets and 13.8-69-161-kV substation located on a greenfield site. The project included site preparation, foundations, service/control building, SCADA interface, assembly and installation, substation, natural gas and water supply interface.

Substation No. 3
City of Gardner, KS

The project included a new 161-12.5-kV distribution substation, the expansion to a 161-kV ring bus configuration of an existing 161-12.5-kV substation and a new 3 mile 161-kV steel pole transmission line with 12.5-kV under build to connect the two substations.

Four Combustion Turbine Generators - West Gardner Generating Station
KCP&L

This project included four 80-MW GE gas turbine generator units located on a greenfield site. The project included site preparation, detention basins, foundations, service/control building, SCADA interface, assembly and installation, substation interface, natural gas and city water interface.

Unit 1 & 2 Control System Upgrade - Chamois Station
Central Electric Power Cooperative

Sega was responsible for installation engineering, as well as the design and testing of the application software for the control systems and the operator interface. Obsolete control and instrument systems were replaced on two coal-fired generating units. Full implementation of the new distributed control system included the installation of 144 new transmitters, I/P converters, positioners, signal converters, and miscellaneous control devices.

GT 2 - Dayton Avenue Station
City of Ames, IA

Sega was the owner’s engineer for detailed installation design, procurement, construction management & startup. This project included the addition of one 31-MW Simple Cycle Combustion Turbine Generator (GE LM2500+).

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Beaver Channel Transmission Line
Archer Daniels Midland

The 69-kV line design included two, three-phase circuits of 2226-T2 “Bluejay” ACSR and provision for one future line. Sega’s design services also included Economic Conductor Study, Plan and Profile Drawings, Construction Contract, Steel Pole Specification, Conductor Specification, Transmission Materials BOM and Specification, Engineering Support During Construction, Aerial Mapping and Surveys, Coordinating Mapping and Photogrammetry Process, Geotechnical Specification, and Foundation Design.

Co-Gen 69-kV Substation
Archer Daniels Midland

Sega’s design scope for this greenfield substation included fifteen, 69-kV breakers in a breaker-and-a-half scheme, steel structures, two GSU transformers, three auxiliary transformers, relay protection schemes and panels, SCADA, multiple line-ups of 7200-V switchgear, and 7200-480-V transformers. In addition to designing 69-kV lines to feed the adjacent corn processing plant, the design included tying into the local electric utility and provisions for future lines and transformers.

Riverton Unit 12 Combustion Turbine Addition
Empire District Electric Company

The project included the installation of a 155-MW Siemens V84.3A2 combustion turbine and auxiliaries for a new unit at an existing power generation facility. This addition increased the facility’s overall capacity to accommodate increasing customer demand. Sega was the EPC contractor and was responsible for all engineering, procurement of the balance-of-plant equipment, and installation and start-up services.

Grindstone 161/69-kV Transmission Line
City of Columbia, MO

The project included a new triple circuit steel pole transmission line approximately 2.75 miles in length, two 161-kV circuits and one 69-kV circuit on single steel pole structures. Tangent structures were direct embedded with large angle and dead-end structures placed on reinforced concrete drilled piers.

69-kV System Improvements
City of Chanute, KS 

Replacement of approximately two miles of 138-kV transmission line (energized at 69-kV). Installation of a new 69-12-kV transformer and 69-kV buswork at Plant 3 and the installation of a new 69-12-kV transformer, 69-kV buswork, and 12.5-kV switchgear at Plant 2.

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Geographic Information Systems
City of Chanute, KS

The project included the creation of a Geographic Information System (GIS) that contains Electric, Gas, Wastewater, Water, and Communication assets with Environmental Systems Research Institute (ESRI) software. Sega was the owner’s engineer and was responsible for the conversion of existing AutoCAD drawings (circa 2000) into the ArcGIS database and maps. Sega also setup and maintains the GPS data collection efforts allowing the city of Chanute to update the database and maps.

Nearman Creek Power Station, CT Addition Project
Kansas City, KS Board of Public Utilities

Sega assisted BPU with the design procurement and construction of a new 80-MW combustion turbine generator (GE-7EA). Sega provided detailed design of the unit, procurement of equipment, construction services, site construction oversight, and startup commissioning services for the CT4 project.

Unit 1 Control System Upgrade - Leland Olds
Basin Electric, Bismarck, ND  

Sega  replaced an existing distributed control system (DCS), incorporating into the controls new subsystems and coincident turbine and boiler upgrade projects.

Sega’s services included the preparation of equipment and installation specifications and drawings, the design and testing of the application software for the controls systems, and field services to administer the installation contract and checkout and tune the new controls.

McCartney Generating Station, CT Addition Project
City Utilities of Springfield, MO

This was a Greenfield project that included two 50-MW gas turbine generators and substations.  The project also included site preparation, foundation, maintenance/control building, gas compressors, and fuel oil storage.  Sega provided design and construction services on this project.

Gas Turbine Addition, City of Chanute, KS

Installation of a single 50-MW Siemens Westinghouse combustion turbine generator at an existing site.

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Unit 1 Control System Upgrade
City of Sikeston,  Sikeston, MO

Obsolete control and instrumentation systems for Unit 1 were replaced with a modern distributed control system (DCS). 

Sega’s services included the preparation of equipment and installation specifications and drawings, as well as the design and test of the application software for the control systems and for the operator interface. Specifications were also prepared for the procurement of the new protective relays.

A low-fidelity permanent simulator was also designed and configured by Sega. This simulator was used to check out the control system configuration software and to conduct operator training prior to the upgrade of the unit.

Unit 1 Control Retrofit - Nearman Creek Power Station
Kansas City Board of Public Utilities,  Kansas City, KS

Obsolete control and instrumentation systems for Unit 1 were replaced with a modern distributed control system (DCS). 

Sega’s services included the preparation of equipment and installation specifications and drawings, as well as the design and test of the application software for the control systems and for the operator interface. Specifications were also prepared for the procurement of the field equipment such as transmitters, I/P positioners, miscellaneous valves and control drives.

A low-fidelity permanent simulator was also designed and configured by Sega for this project. This simulator was used to check out the control system configuration software and to conduct operator training prior to the upgrade of the unit.

Sioux Generating Station, Units 1/2 Controls Upgrade
AmerenUE, St. Louis, MO

AmerenUE first selected Sega to prepare a conceptual design to define the scope and establish budget and schedule requirements for upgrading controls on these two 488-MW supercritical units.  Upon completion of the conceptual design, Sega was retained to provide all engineering services required for this project.  

Units 1/2 Controls Upgrade and Plant Monitor Information System
Associated Electric Cooperative, Clifton Hill, MO

Replaced existing control and information systems for two cyclone-fired units to resolve equipment obsolescence problems and to provide the more complex control strategies required for fuel conversion to western coal. 

These services began with a conceptual design to define project requirements and included equipment and installation specifications as well as preparation of all application software, construction review, and startup.

Original panelboards and instrumentation were replaced with "touch-screen" CRT-based operator interface devices. HVAC and lighting systems were upgraded to meet the requirements of the new operator interface and distributed control system equipment.

In addition to meeting the control objectives, the new distributed control system provides operating information to key plant management and engineering personnel through PC-based supervisory stations connected to a plant-wide LAN.

Power Production Improvement for Blue Valley and Missouri Valley Station CTs
City of Independence, MO

Performed a wide variety of plant betterment projects.  Worked on cooling towers, control system replacement, continuous emission monitor, combustion turbines, boiler overhauls, precipitator upgrades, new coal feeders and coal handling upgrades, and several other miscellaneous projects.

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Package Boiler Replacement
City of Coffeyville, KS

Sega replaced two existing field-erected boilers at the municipal power plant with one field-erected package boiler.

Council Bluffs Controls Upgrade and Plant Monitoring and Information System
MidAmerican Energy Company, Council Bluffs, IA

Replaced obsolete control and monitor systems on a nominal 700-MW coal-fired unit with a microprocessor-based distributed system.  Approximately 30 linear feet of conventional operator benchboard was replaced with a CRT/keyboard-based operator interface center.  Control room renovations included new offices and new lighting as required to meet ergonometric criteria.  After the unit was started, Sega was commissioned to develop and install a new plant-wide performance monitoring and information system.

Package Boiler and Services at Prairie Creek, Sixth Street, and Sutherland Stations
Alliant Energy - IES Utilities, Cedar Rapids, IA

Perry Station Control Retrofit
Indianapolis Power & Light Company, Indianapolis, IN

Replaced obsolete electromechanical instruments and controls with microprocessor-based distributed control system for combustion control and flame safeguard on Perry "K" Station, Units 11 through 16. Configuration software was designed at Sega's staging facilities, then loaded and debugged on-site.  Start-up services included system checkout, operator training, and delivery of customized operation manuals.  By providing a full-scope engineering service, Sega guaranteed single-source accountability for the reliability of the new system.

Montrose Station Controls Replacement
Kansas City Power & Light Company, Clinton, MO

Replace outdated pneumatic control system for three 175-MW coal-fired units with microprocessor-based distributed control system.

Sega wrote technical specifications for purchase of the control system, including electronic transmitters to replace pneumatic transmitters and control drives to replace outdated control drives. Sega prepared construction documents and provided on-site consulting for installation of the new controls and associated equipment. To ensure that the control system met the unique requirements of Montrose Station and provided single-source accountability for system operations, Sega custom designed the configuration software and wrote the operation manuals. A complete checkout for both hardware and software was completed at Sega’s offices prior to installation. Using a dynamic mathematical model of the plant, Sega staged computer simulations to train system operators prior to startup. Actual installation and startup (startup was performed by Sega control specialists) took less than five weeks for each unit. Using Sega’s custom-designed software, the computer-based system provides more precise control, better turndown, more flexible operations, and improved emissions control.

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Montrose, La Cygne, Hawthorn, Iatan, and Northeast CT
Kansas City Power & Light Company, MO and KS

As part of a miscellaneous engineering services agreement with KCPL, Sega has performed a number of projects.

Power Plant Improvement Projects (Plant Betterment)
St. Joseph Light & Power Company, St. Joseph, MO

Sega has provided engineering services in support of a number of power plant improvement projects at the St. Joseph Light & Power Company Lake Road Station.  They were part of a miscellaneous engineering services agreement.

Grand Avenue Plant ST Generator and Precipitator Replacement
Trigen Energy Corporation, Kansas City, MO

Trigen's coal-fired utility plant in downtown Kansas City cogenerates chilled water, steam, and electricity.  The steam and chilled water are distributed to industrial and commercial customers in this area.

Steam Turbine Generator
The Grand Avenue Plant was supplying steam direct from a high-pressure boiler through a pressure-reducing valve (PRV). To improve the economics of the plant, a 5-MW back-pressure steam turbine electric generator was used to replace the PRV. Sega designed the foundation, piping systems, and electrical connections for the turbine generator. Sega prepared plans and specifications for bidding and construction of the balance-of-plant structures and systems to support the turbine generator. Sega provided full-time on-site construction management to coordinate the various suppliers and contractors involved in the project. We also coordinated the start-up activities and performance testing.

Precipitator Replacement
The precipitator used to clean the coal-fired boilers flue gases was destroyed by fire. The plant was operating on high-priced natural gas backup fuel. A replacement precipitator was furnished and installed on a fast-track basis. Sega designed and prepared bid documents for precipitator auxiliaries including new ductwork, chimney repairs, platforms, lighting, and architecture.

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Unit 1 Upgrade
Power South Electric Cooperative , Leroy, AL

Sega provided engineering services at the Charles R. Lowman Power Plant.  We replaced the following: coal feeders, burner management system, precipitator, and boiler insulation and lagging.  The project also included converting the boiler from pressurized to balance-draft operation and other boiler modifications.

Waste to Energy
Alliant Energy, Cedar Rapids, IA

Sega helped with conceptual design, detailed design engineering, plans and specifications, equipment procedures, controls configuration, and complete startup on this plant. 

The project included a 5-MW turbine generator, precipitator, ash handler, waste-handling facility, fluidized-bed gasifier, steam boiler, cooling tower, and a substation.

Chariton Valley Biomass
Alliant Energy - IES Utilities, Ottumwa, IA

Sega provided engineering, procurement, and construction of the facility to handle the switchgrass going into the boiler at the Ottumwa Generating Station. 

The project needed: building, transformer, motor control centers, de-bailer, belt conveyors, shredders, storage hopper, feeders, blowers, piping, wiring, and controls. 

Controls System Upgrade Units 1, 2, 3, and 4 - Labadie Power Plant
AmerenUE, Labadie, MO 

Obsolete control and instrumentation systems were taken out and replaced on four- coal-fired generating units.  The units are similiar 600-megawatt pulverized-coal drum-type units with identical boilers. 

The following were replaced in each unit: sequence of events, digital alarm monitor, data acquisition, motor control, combustion control, turbine controls (Units 1 and 2), interfaces, BTG consoles and panels, and transmitters.

Combustion Turbine Generator Set Addition - Venice Power Station
AmerenUE, Venice, IL

The project had Sega provide engineering services for the addition of a new 50-MW combustion turbine generator set at the Venice Plant. 

Also included were site preparation, foundation, service building, gas compressor, and fuel oil storage.

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Unit 4 Control Systems Upgrade - Judson large Generating Station
Kansas City Power & Light Company, Dodge City, KS

Sega was hired to replace the existing outdated control and instrumentation systems for one gas-fired 150-MW unit with a microprocessor-based distributed control system. 

The following were replaced: combustion controls, burner management, turbine controls, data acquisition, alarm/sequence of events, motor controls, and BTG board.

Unit 2 Control Retrofit - Quindaro Power Station
Kansas City Board of Public Utilities,  Kansas City, KS

Sega was selected to replace the existing control system for a 145-MW pulverized-coal-fired steam generating unit and three combustion turbine generators. 

The following were replaced: combustion controls, burner management, turbine controls, data acquisition, alarm/sequence of events, motor controls, and BTG board.

Boiler Replacement
City of Coffeyville, KS

The city decided to replace the inefficient existing boilers with a field-erected package boiler rated at 200,000 lb/hr, 900 psi, 900 degrees F. 

The project included asbestos removal, lunch/training room, structural steel/foundation, demolition of existing boiler, deaerating heaters, controls, control room expansion, main steam piping to turbine generator, and repair and place in service feedwater heaters.

Unit 1 Controls Upgrade - Asbury Plant
Empire District Electric Company, Asbury, MO

Sega replaced obsolete control and instrumentation systems on Unit 1, a 205-MW cyclone-fired drum-type coal-fired unit. 

The following were replaced: combustion controls, burner management, turbine controls, data acquisition, alarms, bottom ash controls, and motor controls. 

Controls Upgrade
Energy Systems Company, Omaha, NE

The project was to replace existing obsolete controls and instrumentation systems for boilers, chillers, balance-of-plant, and SCADA. 

The following were replaced: combustion controls, steam turbine controls, steam metering, boiler feedwater controls, condensate system controls, chiller controls, chilled water distribution system controls and metering, cooling tower controls, condensing water system controls, SCADA/data acquisition system, networking of operational data, and plant HVAC controls.

Controls Upgrade - North Denver Station
Hastings Utility, Hastings, NE

This project  was a distributed control system (DCS) retrofit with boiler upgrades, auxiliary power upgrades, and turbine water induction protection system (TWIPS).

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For a detailed description of any project, please contact Steve Hinderliter at 913-681-2881.