Second SCR at Hayden coal plant in Colorado to be completed in 2016

Public Service Co. of Colorado told the Colorado Public Utilities Commission in an April 8 update that new emissions controls at the coal-fired Hayden power plant are well along in construction.

The Hayden controls are part of this Xcel Energy (NYSE: XEL) subsidiary’s compliance with the legislatively-imposed Clean Air-Clean Jobs Act. This report is the eighth semi-annual status report on the Hayden 1 and 2 Emission Controls installation and describes the status of the project as of Dec. 31, 2015.

Sargent & Lundy was selected to provide consulting and balance of plant engineering services. Several studies of current operating conditions and impacts of the required new equipment have been completed. It has been determined no additional upgrades to the existing duct or scrubbers is required.

The contract for the Selective Catalytic Reduction (SCR) equipment was awarded to Hitachi Power Systems America Ltd. Detailed engineering continues and is approximately 99% complete. Initial deliveries began in March 2014.

Upgrades to the existing Induced Draft Fans was required. Unit 1 required fan tipping and upgraded motors. Contracts were executed with TLT Babcock for the Unit 1 Fan Tipping and Teco-Westinghouse for the Unit 1 Fan Motor Upgrades. Unit 2 will require new fans and motors. A contract was executed with Howden North America for the Unit 2 Fan and Motor Upgrades.

Requirements for procurement of other equipment including, long lead time electrical equipment and long lead time mechanical equipment have been prepared. Construction Update Contracts for Foundation and general construction were executed with The Industrial Company (TIC).

Construction activities for Unit 1 foundations were completed in December of 2013. The erection of SCR equipment began in May 2014. The Unit 1 SCR tie-in outage was completed in May 2015. The final acceptance of Unit 1 SCR was in November 2015. Construction activities for Unit 2 foundations began in the fall of 2014, and completed in April 2015. The erection of the Unit 2 SCR began in May 2015 with completion in 2016.

PSCo had provided initial cost estimates for the project of $73.9 million for Unit 1 and $91.0 million for Unit 2. The company revised its budget for both Units 1 and 2 reflecting the discussion above for the induced draft fans, which resulted in a slight modification of the estimates for both Units 1 and 2 adjusting the original estimates to $74.8 million and $90.5 million respectively. These revised estimates are reflected in this report as the “Baseline Budget.”

Says the Xcel website about this 446-MW, two-unit plant: “Hayden Station controls air emissions with multiple technologies, including baghouses, dry scrubbing systems and low-NOx burners. Baghouses act like giant vacuum cleaners, removing particulate emissions from the flue gas by more than 99 percent. Dry scrubbing systems reduce sulfur dioxide emissions by about 85 percent, and over-fire air equipment reduces nitrogen oxide emissions by up to 50 percent.

“Additional controls to further reduce nitrogen oxide emissions at Hayden will be installed on Unit 1 in 2015 and on Unit 2 in 2016 under the Colorado Clean Air – Clean Jobs Act, supported by Xcel Energy. That makes Hayden one of the cleanest coal-fired generating stations in the region with advanced emissions control equipment. Hayden Station also discharges no water offsite.”

The two other co-owners of Hayden are PacifiCorp and the Salt River Project.

About Barry Cassell 20414 Articles
Barry Cassell is Chief Analyst for GenerationHub covering coal and emission controls issues, projects and policy. He has covered the coal and power generation industry for more than 24 years, beginning in November 2011 at GenerationHub and prior to that as editor of SNL Energy’s Coal Report. He was formerly with Coal Outlook for 15 years as the publication’s editor and contributing writer, and prior to that he was editor of Coal & Synfuels Technology and associate editor of The Energy Report. He has a bachelor’s degree from Central Michigan University.