OVERVIEW

Delta provided mechanical and electrical engineering at the DuPage County Power Plant on two separate projects:

• Power Plant Boiler #2 Upgrade Project
• Power Plant Chiller Replacement Project

Power Plant Boiler #2 Upgrade Project

Delta provided mechanical, electrical, & controls engineering design services for upgrades to boiler #2 at the DuPage County Power Plant.

Boiler #2 (model DW-86) was a hot water generator with a capacity of 45,000,000 BTUH. All of the power plant’s hot water generators at the time were dual-fuel, gas-oil fired units.

Scope of work, including PS&E, involved the following:

• Reviewed all existing electrical and piping work
• Surveyed all components such as actuators, linkage, limit switches, shaft extensions, motorized shutoff valves, and meters
• Removed and replaced the existing pneumatic controls & safety devices
• Installed a new PID controller for automatic fuel and air flow regulation. The controller also manages metering, cross limiting combustion, and O2 trim.
• Replaced the two boiler pressure relief valves
• Modified electrical and piping work where needed

Power Plant Chiller Replacement Project

Delta provided electrical engineering design services for the replacement of chillers, starters, and associated equipment at the DuPage County Power Plant. Four existing chillers (3-1,000 ton; 1-300 ton) were replaced with three new chillers (1-2,000 ton; 2-1,000 ton).

The electrical engineering scope included:

• Reconfiguration of existing 5 kV switchgear to accommodate 600A power to new chillers
• Reconfiguration of existing Variable Frequency Power Supply (VFPS, 600A/480V/3-PH) to accommodate power to two new 200HP chilled water pumps
• Reconfiguration of existing Motor Control Center (MCC, 600A/480V/3-PH) to accommodate power to new water pumps and fans
• Design was provided such that the power plant would remain in operation throughout entire demolition process