Zachry Engineering began as an engineering department within an operating utility responsible for central station power plants. We have designed several large steam power plants fueled by coal, gas and oil.

 

Coal Generation

Our most recent coal design experience includes pulverized coal and circulating fluidized bed technologies.

 

Our coal design experience includes:

• detail plant design work
• final site selection
• preliminary engineering
• site layout
• plant layout
• capital cost estimates
• pro-forma cost analysis
• permitting support
• engineering support for project financing
• final feasibility study documents
• project coordination

 

Our coal plant experience includes EPC projects that were done in consortium with contractors and equipment suppliers. Completed plants serve as a starting point for new projects, or we can apply the basics of one of our coal reference designs as the starting point for a power plant.

 

Gas Generation

Project and design work on gas-fueled power plants have included simple cycle and combined cycle projects representing more than 17,000 megawatts of capacity.

 

Many of our gas generation plants have been EPC projects that were done in joint ventures with contractors. These projects have utilized gas turbine-generator technology from all of the predominant equipment suppliers. The size of a Zachry Engineering gas turbine project ranges from 40 megawatts to 1100 megawatts, and the project locations stretch across North America.

 

With a large variety of gas-fueled plant designs completed, we have the ability to start quickly with a previous design or from a family of completed reference designs for combined cycle power plants.

 

Environmental Compliance

Zachry Engineering has the proven experience to help clients quickly achieve environmental compliance in the most cost-effective manner through our extensive capabilities and understanding of air quality control systems (AQCS) for fossil-fueled power plants. We have completed dozens of AQCS projects ranging from a few thousand dollars to over $100 million, covering a wide range of technologies and emissions issues.

 

Many projects are retrofits of existing units and must meet the challenges of underground obstructions, limited space, existing equipment demolition and creative ductwork rerouting. The scope of work and services we perform varies on each project, but frequently involves the following services.

 

• Economic Evaluation
• Planning
• Estimating
• Detailed System Design Engineering
• Detailed Steel and Ductwork Design
• Flow Modeling and Pressure Drop Optimization
• Site Preparation and Underground Reroutes
• Equipment Specification and Procurement
• Foundations and Sitework
• Ductwork and Flues
• Procurement
• Design Review
• Electrical and Control Systems
• Project Management
• Budget and Cost Control
• Scheduling
• Construction Management
• Startup and Testing

 

Plant Betterment

We have had a continuous presence in power plants for more than 50 years. Existing power plant engineering service projects have grown to more than 200 projects per year, with total project costs averaging $75 million in the last five years.

 

Individual projects vary from as small as several hundred dollars, to large multi-year, multi-million dollar projects and include engineering studies, preliminary design engineering, detailed design engineering, drafting, surveying, field engineering, procurement, contract management, construction management, construction inspection, startup and commissioning, training, project management and project controls.

 

We have a full complement of engineers and designers in all of the engineering disciplines required to support power plant retrofits.

 

Some of the services we provide for existing power plants include:

• Remaining Life Assessments
• Life Extension
• Plant Upgrade
• Plant Modernization
• Fuel Conversions
• Cycle Conversions
• Changes in Operating Mode

 

Substations

The history of Zachry Engineering includes the design and support of substations for power plants and power delivery networks. In addition to the substations that are associated with new generating plants, we have provided design for a variety of substations at various voltages.

 

Our engineering knowledge and experience was enhanced by the support of a previous subsidiary company that owned, operated and maintained more than 25 substations.