Varo worked in a collaborative effort with a process equipment supplier and the project’s construction contractor to provide balance of plant engineering services for a wet-to-dry fly ash conversion and ash handling system located at a major utility’s coal fired power plant. The integrated team worked with the Owner from early conceptual development of multiple options through the startup, commissioning and system acceptance.
- Varo’s design included civil site work, shallow and deep foundations, retaining walls, pipe bridges, instrument air and service water systems, a building (including MEP) for housing balance of plant equipment, and electrical power supply. Key elements of the project include:
- Worked closely with client permitting department to provide support and coordinate discussions with local, state and regulatory agencies;
- Rerouting of underground utilities and storm water drainage in the very congested and densely arranged plant, and development of the silo storage and truck loading area;
- A new storm water detention pond as well as pavement containment, a collection sump with pumps and underground piping for collection and disposal of contaminated runoff;
- Design of deep and shallow foundations to support the new structures, equipment and piping for the project;
- A new level of structural steel within the existing flue gas ductwork support structures to support approximately 400 feet of the flyash conveying and utility piping as well as an additional 2800’ of pipe bridge with a State Highway crossing;
- Power distribution, control wiring, grounding and lightning protection, and lighting in the plant area and the new silo area.
A major part of the project design involved the generation of a 3D model. This started with a laser scan of the existing facility and used the point cloud output to develop the model. Varo incorporated the work of the process equipment supplier and other consultants into the overall project 3-D model using Navisworks. This allowed for ease of checking for interfaces between work of the various consultants and the existing structures and equipment. Weekly progress meetings allowed the various parties to review 3-D model updates live to facilitate the coordination of work throughout the project.
- Auger cast piles from 18” to 36” diameter for plant area towers
- 48” diameter drilled caissons with a 60” thick concrete cap for silos
- 25’ high by 400’ long soldier pile retaining wall with pre-tensioned tie-backs and precast face panels to retain and active sliding hillside
- Elevated pipe bridges spanning 80’ to 100’
- Enclosed gallery spanning 150’ across State Highway
- All auxiliary steel and pipe supports for five 3200’ long piping runs
- Service water supply routed 3200’ above ground, including a continuous recirculation loop in lieu of heat tracing
- Mechanical (HVAC) and plumbing design
- 500 hp compressors and instrument air routing to support technology equipment
Power Supply System
- EasyPower software
- Four piece pre-fabricated power distribution center and redundant 13.8kV tie-in’s
- Bus differential, over-current relay protection and arc flash analysis and mitigation
For More Information
For more information, related capabilities, or to speak with someone at Varo to discuss how we can help you with your projects, please contact: