Auxiliary Boiler Replacement Project
The Auxiliary Boiler Replacement Project was a critical electrical and instrumentation upgrade at a power generation facility in Eastover, SC. The project involved demolition of the existing auxiliary boiler systems and installation of new electrical feeders, cable trays, instrumentation, and related infrastructure during a constrained 45-day outage window.
Auxiliary Boiler Replacement Project
ITAC’s client faced significant hurdles in replacing the auxiliary boiler’s electrical and control systems at the Power Station:
- Tight outage schedule — All major electrical systems installation had to be completed within a strict 45-day outage period, leaving little margin for delays.
- Long lead times for materials — Critical electrical components and cabling required early planning and coordination to avoid schedule impacts.
- Confined workspaces — Multiple trades (electrical, instrumentation, mechanical) worked in very close proximity, increasing complexity, safety risks, and coordination challenges.
- Comprehensive demolition and reinstallation scope — This included removal of existing 480V feeders, 120V power/control/instrumentation wiring, and grounding systems, followed by extensive new installations.
These factors demanded exceptional pre-planning, supplier coordination, and onsite execution to ensure the project stayed on schedule without compromising safety or quality.
Project at a glance
-
CLIENT
Confidential Utilities Client -
SITE
Eastover, South Carolina -
SERVICES
- Electrical Construction
- Construction Management
ITAC Solution
ITAC provided full electrical and instrumentation installation services as part of the contractor team, focusing on pre-outage preparation, outage execution, and supporting new infrastructure:
Pre-Outage Phase
- Demolition and responsible disposal of all associated existing 480V electrical feeders.
- Complete demolition of 120V power, control, instrumentation wiring, and systems grounding.
Outage Phase — Key installations included:
- Approximately 500 ft of new 10” x 4” aluminum ladder-type cable tray from the existing Baghouse MCC room to the new FD Fan Motor Starter Cabinet in the Aux Boiler Building.
- Approximately 500 ft of new 3/C #350 MCM parallel electrical feeders from the Baghouse MCC room to the new FD Fan Motor Starter Cabinet.
- Approximately 50 ft of 10” x 4” aluminum ladder-type cable tray from the new FD Fan Motor Starter Cabinet to the new 400 HP FD motor.
- Approximately 50 ft of new 3/C #350 MCM parallel electrical feeders from the new FD Motor Starter Cabinet to the 400 HP FD motor.
- New grounding systems for the FD fan motor, systems control cabinet, steel structure, and related equipment.
- Installation of (6) 18” x 18” x 6” NEMA 4X instrumentation field device termination junction boxes.
- Installation of approximately (34) systems analyzers, temperature transmitters, flow transmitters, instrumentation devices, and associated stainless steel tubing.
- Approximately 4800 ft of instrumentation cable.
- Approximately 4000 ft of ¾”, 1”, 2”, and 4” RGS power and control conduit.
- Miscellaneous power and lighting conduit and cabling.
New Oil Storage Building — Additional electrical scope:
- Installation of (2) 8 ft strip lights.
- Installation of (4) 120V convenience receptacles.
- Installation of (1) 30KVA 3-phase transformer.
- Installation of (1) 120/208V distribution panel with 24 circuits.
- Installation of #4 systems bare grounding.
ITAC enhanced project success through improved pre-planning and early material release coordination with suppliers, addressing long lead times and supporting seamless execution during the outage.
Project Results
- Successfully completed all electrical and instrumentation upgrades within the 45-day outage window, minimizing downtime for the Wateree Station.
- Delivered a modernized auxiliary boiler electrical system with enhanced reliability, including new high-capacity feeders, extensive instrumentation, and proper grounding.
- Improved overall project efficiency through better awareness of pre-planning needs and proactive supplier coordination — key lessons applied to future outages.
- Achieved safe, high-quality installation in a challenging, multi-trade environment with no major delays or rework reported.
This project strengthened the facility’s operational reliability while demonstrating ITAC’s expertise in managing complex, time-critical electrical installations in power generation settings.
A Raving Fan
The client was extremely pleased with the end result.
The dedication and passion to succeed from ITAC staff was outstanding. ITAC’s Project management is executed very well , staying on scope and within cost.
– Project Manager | Confidential Client
