Holcomb Station Low NOx Burner Replacement and Separated Overfire Air Installation
Sunflower Electric Power Corporation, Holcomb Station - Holcomb, KS
Replaced original dual register coal burners with Hitachi’s new third generation low NOx burners, which were developed for high combustion efficiency, and installed new separated overfire air (SOFA) system to implement an optimization plan for unit 1 boiler combustion. This coal-fired power station began commercial operation in 1983 and generates 380 MW.
Under Hitachi’s EPC contract, NAES Power Contractors partnered with Hitachi to provide site management, craft labor, and directing of subcontracts for this fast tracked project. Work began in December 2011, and the 42 day outage took place during January/February of 2012. NAES Power Contractors worked approximately 76,000 manhours to complete the project.
- Demolished and removed 25 existing burners, removed sections of furnace tube wall for installation of new SOFA port openings, and other demolition work required for installation of new burners, SOFA system, and associated equipment.
- Removed piping, valves, burner equipment, hangers, insulation, and associated accessories
- Installed 25 new low-NOx burners, including scanners, igniters and other associated equipment
- Installed SOFA system including 9,000 sqft of new ductwork, waterwall openings, SOFA air registers, flow elements, dampers, expansion joints, and other associated equipment
- Installed new support steel, spring cans and 22" knife gate valves for coal conduit
- Installed 10" cooling air and back flow dampers
- Replaced furnace hanger rods and spring cans
- Installed new expansion joints and mounting hardware
- Designed, provided and installed new monorails, catwalks, platforms, ladders, and handrails as required for access to all new equipment and instrumentation
- Conducted pre-startup checkouts of all new systems and assisted in post-installation performance testing