Hawthorn Unit 5 Rebuild

Location: Kansas City, Mo.

Client: Kansas City Power & Light

Completion Date: 2000

Burns & McDonnell provided professional services to rebuild Hawthorn Unit 5. Scope included permitting; detailed design; project management; performance specifications for the new boiler, SCR, dry FGD and baghouse; bid evaluation; and on-site technical support.

  • Permitting
  • Planning, estimating and scheduling
  • Project management, expediting
  • Detailed design and owner's engineer
  • Check-out and startup assistance

An explosion in February 1999 destroyed the Unit 5 powerplant boiler at Hawthorn No. 5 generation station in Kansas City, Mo. Burns & McDonnell was selected as the consultant to assist KCP&L with the rebuild in May 1999.

Due to an aggressive schedule requiring the unit to be operational by summer 2001, Burns & McDonnell started numerous efforts in parallel. Permitting for the new boiler started immediately, and the permit was obtained in just over three months. Conceptual design and preparation of detailed specifications for the boiler and pollution control equipment also started immediately. The engineer-procure-construct (EPC) specification was created, issued and the successful bidder selected within three months. Burns & McDonnell prepared the EPC bid documents and assisted KCPL with the bid evaluation and contract negotiations with the successful bidder.

Burns & McDonnell performed extensive on-site investigations, assessments, and engineering for the existing turbine building, turbine and balance of plant equipment. The scope also included detailed foundation design for the all new boiler and air pollution control equipment. Burns & McDonnell engineers and technicians performed detailed electrical controls and interface design as well as continued project management and on-site technical support activities.

The existing steam turbine generator was upgraded to increase the electrical output of the unit.

  • Fast track coal-fired design and construction
  • 100% PRB fuel
  • Very low emissions
  • New control room and control system
  • Conversion of existing precipitator to pulse jet baghouse
  • Capacity upgrade