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Comanche Unit 3
Xcel Energy has begun construction on its first new coal-fired electric generation unit in nearly 30 years. Comanche Station near Pueblo, Colorado, is the site for our 750-megawatt generating unit. The new unit will use a highly efficient supercritical boiler and all units will have state-of-the art emission controls. We will more than double the plant's electricity output while improving overall air quality. To help you quickly find what you’re looking for, here are some links.
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| Photo simulation of Comanche station, with the proposed Unit 3 at right |
Fall Construction Marks Completion of Milestones
Despite the impact of last winter’s snow and cold weather, construction on Comanche Unit 3 reached five key milestones last fall. In addition, hiring of skilled contractors is keeping up with demand, although locating employees continues to test the ingenuity of hiring managers as they search far and wide for qualified applicants. The completion of the project milestones was significant. Work on the structural steel for the boiler, a large, and key, project component, was completed in September.
On the emissions side, in November final ductwork was installed in Unit 2 for the lime-spray dryer that controls sulfur dioxide (SO2). Also in November, mechanical work was completed on Unit 2’s low NOx burners that will control nitrogen oxide (NOx). Finally, in December subcontractor GEA Power Cooling completed the erection of the cooling tower, yet another important, and visible, piece of the project. December also saw completion of the installation of the bridge crane. The crane has been placed into service, which will significantly help with the erection of the turbine generator.
As has been mentioned in the past, there are three major components on this type of project: engineering, procurement and construction. Comanche 3 engineering and design are now 95 percent complete and efforts are being focused on incorporation of final vendor data and finalizing electrical and controls design. Even with material shortages and tight manufacturing deadlines, procurement activities are about 76 percent complete with emphasis on electrical equipment delivery and final boiler pressure parts delivery, among other items.
Overall, construction progress is about 47 percent complete.
Search for Employees Continues
As project construction increases, so do the measures of human endeavor: thus far, over 2.9 million man-hours of work and 1,250 employees now on board. While employee performance has been good, continuing to attract qualified workers continues to be a challenge. Currently, 70 percent of the contract employees working on Comanche 3 are from the local area that stretches from Colorado Springs to Walsenberg, Colo. To meet the projected peak number of 1,500 employees this spring, hiring managers will continue to search locally and nationally, especially for sought-after boilermakers and pipe-fitter welders.
For more information on Comanche 3, visit the links below:
| Comanche 3 under construction. |
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| Erecting steel at the Crusher building. |
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| Pouring the pier caps. |
Plant Partners and Contractors
As with any major construction project, Comanche 3 will be built through the expertise and teamwork of Xcel Energy, its partners, and contract specialists such as these.
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Intermountain Rural Electric Association
Intermountain Rural Electric Association (IREA) of Sedalia, Colo., will own about 25 percent of the output, estimated to be about 190 megawatts.
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Holy Cross Energy
Holy Cross Energy is another project partner. It will own about eight percent of the output, estimated to be about 60 megawatts.
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Shaw Stone & Webster
The contract for the engineering, procurement, and construction portion of Comanche 3 has been awarded to Shaw Stone & Webster of Baton Rouge, Louisiana. Shaw’s contract includes the erection of the steam turbines, and supplying and erecting associated plant systems, including piping, pumps, heat exchangers, and electrical equipment. In addition, Shaw will be involved with the engineering and installation of concrete foundations and other civil and electrical works for the plant.
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The Babcock & Wilcox Company
The Babcock & Wilcox Company (B&W) has received a contract for engineering, materials, and start-up commissioning of three dry flue gas desulphurization (FGD) units. B&W will supply the FGD systems, commonly called scrubbers, for each unit, including mercury removal sorbent injection systems, ash recycle systems, flue work, and structural steel, as well as a common pebble-lime unloading and storage system and a common lime-slaking system. B&W also will supply a pulse jet fabric filter and induced draft fans will also be supplied as well as construction services.
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ALSTOM
Xcel Energy has awarded ALSTOM the contract to design, supply, erect and commission a high-efficiency, supercritical boiler for the company’s planned 750 MW Comanche 3 generating unit. Alstom is a global leader in power generation and rail transport infrastructure.
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Mitsubishi Heavy Industries
We’ve also selected Mitsubishi Heavy Industries (MHI) to supply the turbine for Comanche 3. MHI is a global provider of products and services for the power and engineering, transportation and security, and other industries.
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Hiring Information
For information about construction jobs building Comanche 3, contact the Colorado Building and Construction Trades Council at 303-936-3301.
Project Timeline
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Xcel Energy announced plans to build Comanche 3 in Least-Cost Resource Plan
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April 30, 2004
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Colorado Public Utilities Commission approved Comanche 3
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January 21, 2005
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Xcel Energy requested permission to build new transmission link
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February 16, 2005
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Labor Agreement reached
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June 9, 2005
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| All necessary permits received |
September 30, 2005 |
| Site preparation work begins |
September 2005 |
| Primary contractor selected |
January 2006 |
| Construction begins on unit 3 |
January 2006 |
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Construction begins on unit 1 and 2 emissions controls
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Fall 2006
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Units 1& 2 emissions controls installed
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November 2008
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Transmission line in service
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May 2009
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Unit 3 construction complete and in-service
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Fall 2009
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Environmental Controls
Comanche Unit 3 will feature state-of-the-art emission controls. We will also install additional emission controls both on the two existing units at the plant. As a result, overall sulfur dioxide (SO2) and nitrogen oxide (NOx) emissions at Comanche Station will be lower than they are today, even when electric generation at the entire facility more than doubles.
For more information about the environmental controls planned for Comanche 3, download the air permit fact sheet (439K PDF) or the environmental settlement fact sheet (44K PDF). For complete information about air emissions performance please see the Comanche Station Air Emissions page.
Low Water Use
A low water use system for Comanche Unit 3 will use both water and air for cooling, which reduces water use by about half. The Pueblo Water Board has determined that adequate water supplies are available for the new unit.
Local Economic and Environmental Benefits
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Project cost
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$1.3 billion
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Labor costs
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$250 million
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Costs for additional emissions controls on existing units 1 and 2
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$127.9 million
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Construction jobs
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1,000
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Additional full-time plant jobs
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40
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Total Annual air emissions reductions
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10,000 Tons Sulfur Dioxide
2,5000 Tons Nitrogen Oxide
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Initial tax payment to the City of Pueblo
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$13 million
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Annual tax payments to Pueblo during the first ten years of operation
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$10 million
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Current annual taxes to Pueblo (includes County, City, special districts and schools)
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$4.5 million
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Donation for school districts for diesel emissions reductions on buses
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$250,000
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Donation to Colorado Department of Public Health and Environment for mercury reduction efforts at Rocky Mountain Steel
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$100,000
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Power Use
The new unit at Comanche Station will serve customers in Colorado. That includes Xcel Energy’s residential and business customers as well as our wholesale customers, including: Aquila in Pueblo, Holy Cross Energy in Glenwood Springs, Grand Valley Power in Grand Junction, Yampa Valley Electric in Steamboat Springs, Intermountain REA in Sedalia, and the cities of Julesburg, Burlington and Center.
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