Warren Kennedy

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Warren Kennedy
Senior Vice President/Marketing and Sales Director
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P: 816-822-3384
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Boiler Replacement - Cheyenne

Boiler Replacement - Cheyenne

Location: Cheyenne, Wyo.

Client: Frontier Refining

Completion Date: 2008

Frontier Refining selected Burns & McDonnell to provide front-end planning (FEP) and lump sum engineer-procure-construct (EPC) services for its No. 3 boiler replacement project. The project consisted of a new 150,000-pound-per-hour saturated steam packaged boiler operating at 275 pounds-per-square-inch-gague (psig). A new boiler replaced two previously existing rental boilers. The new boiler was designed with ultra-low nitrogen oxide (NOx) technology and flue gas recirculation to meet the submitted state permit requirements for NOx and CO2 emissions. This effort allowed Frontier to meet current Wyoming and federal emissions requirements.

  • Front-end engineering
  • Detailed design
  • Procurement, inspection and expediting
  • Construction
  • Commissioning and startup assistance

Burns & McDonnell was initially contacted by Frontier Refining in late first quarter 2007 to provide FEP-1 engineering services for the project. Burns & McDonnell worked with several boiler manufactures to identify and specify a packaged boiler unit that would provide the required rates and meet the emission requirements. Burns & McDonnell worked closely with the Frontier Refinery project team to develop an estimate and fast-track execution approach to support the decommissioning of existing rental boilers, which were mandated by the state to be removed by fourth quarter 2008.

Burns & McDonnell specified the new 275-psig boiler for Frontier during FEP-2/3 and served as the owner’s engineer for the design, fabrication and delivery of the boiler.  Burns & McDonnell was responsible for the development of a definitive cost estimate, funding and development of a detailed subcontracting execution plan to complete the project.  After FEP-2 and FEP-3 phases were completed the project was converted to a lump-sum EPC contract.

During detail design, Burns & McDonnell worked closely with Frontier and the boiler manufacture to fabricate the packaged boiler unit on a fast-track schedule and deliver equipment to the site early.  Burns & McDonnell utilized laser scanning technology integrated with PDS modeling to design the piping and electrical systems required to integrate the new boiler into the existing plant steam system.  Burns & McDonnell specified the building of the continuous emissions monitoring system and all other auxiliary equipment required to support the boiler and was responsible for the procurement of all material.

Burns & McDonnell used multiple, lump-sum subcontractors during construction.  The construction scope was divided in four distinct packages:

  • Civil/site development
  • Mechanical
  • Electrical and instrumentation
  • Insulation, painting and electric tracing

This approach allowed the use of highly skilled and specific craft labor from locals.

It was critical that the new boiler be operational and online before the onset of the 2008 winter. Burns & McDonnell worked through various schedule challenges to deliver a fully operational boiler in mid-November 2008, 14 months after the date of purchase of the boiler unit.

  • Fast-track specification and procurement of package boiler unit
  • Integrated laser scanning and plant design system modeling
  • Competitive, lump-sum subcontracting approach