Greenheck Project ProfileWeston 4, A 500 Megawatt Power PlantMarathon County, WI (Villages of Rothschild and Kronenwetter)
OwnerWisconsin Public Service Corporation, a subsidiary of WPS ResourcesRothschild, WI
Engineering and ContractingFirms:
Design Procurement and Start-up:Black & VeatchOverland Park, KS
Superstructure HVAC:Tweet-Garot Mechanical IncorporatedGreen Bay, WI
Greenheck RepresentativeVyron CorporationGreen Bay, WI
exhaust the required air volumeand to maintain acceptableindoor air quality andtemperatures. The ventilationequipment must be capable ofwithstanding industrial levelbuilding vibrations, and havelow maintenance requirements.
plant will join three otherWisconsin Public ServiceCorporation coal-fired powerplants that have been inoperation since Weston 1 beganfeeding the grid in 1960. The$752 million Weston 4 plant willuse clean coal technology andstate-of-the-art emissioncontrols tominimizeenvironmentaland socialimpacts. Thegiantsuperstructurerequires specialventilationequipment to
Collaborate with multiplefirms to design andmanufacture a unique,direct-drive “Utility Duty”sidewall fan.
Design the fan to be easilymounted between existingbuilding framework (90” x90”) and provideconvenient, side accessto the fan and dampers.
Deliver 103 housed fans inphases over six months tomatch the contractors’precise scheduling needs.
Scheduled for completion in2008, the 500 megawatt Weston4 coal-fired electric generation
Above: Construction well underway at the 500Megawatt Weston 4 facility
Right: Greenheck’s Utility Duty propeller fans installed.
The Ventilation Challenge
Greenheck’s custom-designed special direct drive “Utility Duty” propellerfans in a 90” x 90” wall housing
knowledge we needed to meetthe unique ventilationrequirements.” This projectbecame a reality, he said,“because of the superiorcoordination, prototyping, andon-site visits.”
involved, the uniqueinstallation and ventilationrequirements and thedemanding installationschedules. Representatives fromall parties were pleased withGreenheck’s role in the project.
Jay Swoboda, projectsuperintendent from Tweet-Garot Mechanical Incorporatedpraised the teamwork of allparties. “Greenheck’sexperienced engineers had the
Greenheck’s custom-designedfan unit with utility dutyconstruction exceeded thedesign criteria specified. The103 units have all beendelivered on time to match thecustomer’s installation needs,and all fans will be fullyoperational for the start-up ofthe 500 megawatt power plant.Completing these tasks provedto be a significant challenge,because of the multiple firms
on-site visits from thecontractor and electricianensured everything was wellunderstood by all parties,paving the way for an efficientinstallation process. The visitsand prototypes helped thecontractors fully understandhow the units were designedand built and allowed them topractice installing and wiringthe units in a controlledenvironment. The final designincorporated a special directdrive utility duty propellerhoused in a specially designed90” x 90” wall housing. Thecustom blade and pitchpropeller met the air, sound,and horsepower requirements.The unique oversized accesspanels provide a means for
Custom-built Direct Drive“Utility Duty” sidewallpropeller fan and housingwith easy access
With guidance fromGreenheck’s local representative,Vyron Corporation, the project’sengineers selected Greenheck asthe supplier of both the fansand the dampers based on theirability to design a customproduct that would meet thebuilding’s unique requirements.The project demanded multiplefull-scale prototypes to be builtwithin a strict timeline toensure that the design matchedspecific requirements. Engineersfrom Black & Veatch providedexcellent detailed guidelinesensuring all components of thedesign were sufficient. Several
P.O. Box 410 • Schofield, WI 54476-0410 • Phone (715) 359-6171 • greenheck.comCopyright © 2006 Greenheck Fan Corp.
September 2006
Greenheck’s Solution
The Results
servicing and maintaininginternal components includingGreenheck’s industrial controldampers (Model ICD-45,utilizing a two-actuator drivesystem). All damper units wereprovided with single pointwiring to reduce the labor inputrequired by the installingcontractors, Tweet-GarotMechanical Incorporated. Thesuperstructure required 103 ofthe mammoth fan units with atotal weight of over 50 tons.Lifting lugs were installed priorto the units being shipped toallow for easy installation of thelarge housed fans. Two separatelifting configurations weredesigned to allow forinstallation flexibility within thesuperstructure.
