Electric Utilities

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.

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 Power Station
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
Alabama Electric Cooperative, Inc. , 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
Aquila Networks, 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
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).

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