2. Presentation Outline
MN MERP Overview
Allen S. King Project Schedule Overview
Status Update ( including progress photos)
Key Remaining Activities
Influences – Internal & External
3. MN MERP Overview
Emissions Reduction Rider signed into law: Summer 2001
Project development: September 2001 – May 2002
Initial proposal filed with MPUC: May 2002
MERP Project Proposal filed with MPUC: July 2002
Regulatory review and public hearings: Sept 2002 –
November 2003
Settlement Agreement executed: November 2003
— King Rehabilitation $382 M May 2007
— High Bridge Combined Cycle $395 M May 2008
— Riverside Repower $212 M May 2009
MPUC Approval: December 18, 2003
4. King Plant Rehabilitation
Install new state-of-the-art pollution control equipment,
rebuild the existing boiler, replace the existing steam turbine,
install new digital plant control system, and upgrade balance
of plant equipment as necessary.
In-Service Date: May 2007
Capital Cost: Settlement Estimate: $382 million
Emissions Reductions: NOx ~17,000 TPY (89%)
SO2 ~24,000 TPY (91%)
PM ~90 TPY (20%)
HG ~ 15 #/yr (20%)
5. High Bridge Conversion
Install two new natural gas fired combustion turbines operating in
‘combined cycle’ mode to power a new steam turbine. Retire and
demolish the existing facility after the new system is installed.
In-Service Date: May 2008
Capital Cost: Settlement Estimate: $395 million
Emissions Reductions: NOx ~ 4,400 TPY (98%)
SO2 ~ 3,100 TPY (100%)
PM ~ 100 TPY (100%)
HG ~ 66 #/yr (100%)
7. Riverside Repowering
Install two new, natural gas fired combustion turbines operating in
‘combined cycle’ mode to power the existing Unit 7 Steam turbine.
Retire and demolish Unit 8 after completion of the new installation.
In-Service Date: May 2009
Capital Cost: Settlement Estimate: $212 million
Emissions Reductions: NOx ~ 13,000 TPY (99%)
SO2 ~ 12,000 TPY (100%)
PM ~ 540 TPY (100%)
HG ~ 98 #/yr (100%)
12. Functional Organization
Engineering Manager
Co nstruction Man ag er
Russ Girtz Project Management Consult an t
Byron Nordell
Over sight of Design Basis
Wayn e Osat iuk
Safety
Support Data Requests from other
Master Project Schedule
Constr uction Planning
Xcel Ener gy Depts. and/or Business Master Project Cost
Contractor Over sight
Units
Project Scope
Site Support Labor
Inter face with the B&V Project T eam
Project Resour ce Management
Site Services Supervision
Pr ovide oversight of and dir ection to Project Procurement
Inspection and T esting
other technical and engineering
Project Administr ation Project Risk Management
resources on the Project, Including:
Project Collaboration Tool ( Expedition)
Labor Relations with Minnesota Building
Environmental Consultants Project Reporting
T rades Council
King System Engineer s
ES Pr oduction Resources
UEC Engineer ing
Supply Matter Experts
Commercial Manag er
Technical Data Review
Pro ject Director
Construction Suppor t Brian Westerh au s
Subject Matter Experts (SMEs) Supplier Selection Process
Ron Elsn er
Bid Package Creation
Develop and implement
Bid Analysis Process
Pr oject Plan
Contract Administration
External Interface
Technical
A&E Project Management
Financial
Cat hy Weber
Planning and Scheduling
Manage and supervise ES contract.
Implementation and
Ensure engineering activities are carr ied Plant Liaison
constr uction
out to support the pr oject schedule,
Mike Miser
Star t- up
budget, and needs of all pr oject
Distr ibution of:
par ticipants.
General pr oject infor mation
Supervise the engineer ing staff at B&V to
Issue specific and/or task specific information
ensure that budget and schedule are met.
to the plant staff
Pr ovide timely reviews of project
Communicating schedule infor mation to plant
engineer ing status.
personnel
Ensure that all Quality Assur ance and
Participating in and representing plant inter ests in
Quality Control requir ements for
the development and review of the project
engineer ing are met.
Start-Up Manager schedule
Establish and maintain procedur es and
Responsible for determining which groups and/or
process. Rich Goshorn
individual member s of the plant staff should
Develop Star t up & Commissioning
Meet with Xcel Energy Core Management
pr ovide subject matter expertise on given topics
Team to update the project status, note plan and schedule
Accountable for assuring that necessary and
and r esolve ar eas of concern, and provide Oversee development of Start-Up
appropriate groups and/or individuals at the plant
Pr oceedur es
support as requested.
ar e involved in (or, are given the oppor tunity to
Pr oject Reporting Oversee Star t-Up & Commissioning of
pr ovide input to) the project.
Ensure that the ES pr ovided support for all new equipment
Accountable for meeting deadlines for review,
the r equirements in the King Plant
consolidation, and return of data/infor mation/
Rehabilitation Project Settlement
comments from the plant to the project.
Agr eement.
13. Project Approach/ Plan
Collection of distinct sub-projects
Familiarity and experience with sub-projects
Traditional Owner-Managed approach
— Owner’s Engineer: B&V
— Equipment Procurement and Installation: Self Contract
— Construction Management: Utility Engineering
— Commissioning & Start-up: Self Perform
14. Allen S. King Project Schedule Overview
Start of engineering: October 31, 2003
Contracted for major equipment: July, 2004
Groundbreaking: April 22, 2005
Foundations and substructures complete: December 28, 2005
Start of new equipment commissioning: March 2006
Unit comes out-of-service: September 5, 2006
Boiler rebuild & steam turbine replacement: Sept 2006 – Jan 2007
‘First Fire’ on coal: March 2007
Return to service: May 2007 – Project remains on schedule
15. Activities Completed to Date
All environmental permitting complete – State
and Federal
Detailed design and integration: 95% complete
Major procurement: 100% Complete
— Competitive bidding process
— Firm price contracts
Overall construction : ~45% complete
Commissioning & startup:
— Planning: Complete
— Implementation: In progress
Operating procedures development: In progress
Operator training: In progress
16. Procurement of Major Components
AQCS:
– Alstom ECS; Knoxville
– Delivery ~95%; Construction ~60%
SCR:
– Mitsubishi Power Systems; Newport Beach
– Delivery ~95%; Construction ~50%
Boiler:
– B&W; Barberton
– Design ~100%; Manufacturing: 90+%
Steam Turbine:
– Alstom Power; Richmond, Rugby, Elblag
– Design ~100%; Manufacturing 90+%
17. Major Construction Contracts
Substructures: Lunda Construction; Little Chute, WI
SCR Mechanical: Graycor; Homewood, IL
AQCS Mechanical: Graycor
AQCS Electrical: Frauenshuh PD; Minneapolis
DCS/BOP Electrical: Capital; Kansas City
Steam Turbine Area Mechanical: O.J.Boldt; Appleton, WI
Boiler Area Mechanical: B&WCC (pending)
32. Key Remaining Activities
Cooling Towers In-Service: June 1, 2006
AQCS/SCR Mechanically Complete: September 1, 2006
Unit Out-of-Service: September 5, 2006
Demolition Substantially Complete: October 15, 2006
Boiler Pressure Parts Complete: January 31, 2007
First Fire on Gas: February 2007
First Fire on Coal: March 2007
First synch to the grid: April 2007
Unit Return-to-Service: May 2007
33. Influences – Internal & External
Construction labor availability and productivity
in Fall 2006
– Extended periods of multi-shift overtime activities
– May be competing with ourselves for resources (Sherco)
Tight marketplace and commodity price increases
Operator training & initial plant operation
– Rehabilitated plant will have some fundamental
differences from existing configuration.
