Project Scope

BMWC has been executing major boiler outages at NIPSCO facilities for 40+ years. When Unit 12 at NIPSCO’s Michigan City plant came due for a major outage, NIPSCO selected BMWC to execute the complex boiler outage. Several months before the scheduled outage, BMWC formed a preconstruction team consisting of project management and field execution team members to develop a detailed project execution plan.

The outage peaked at 126 direct-hire craft resources, which included 30 pipefitters, 10 ironworkers, 80 boilermakers, and six operators. BMWC’s outage scope included the replacement of the secondary superheat outlet header, convection pass left and right sidewall panels with inlet and outlet headers, convection pass front wall panels with inlet and intermediate headers, and the economizer hoppers. BMWC modified the secondary air duct, economizer outlet flues, and the convection pass front wall casing from the inlet headers to the economizer hoppers. Additionally, the team replaced the #3 and #4 low-pressure condensate heaters, the #6 south high-pressure feedwater heater, the main steam valves, and the steam chest. The boiler outage involved 132 catalyst module change-outs, the installation of three heaters, 8,500 square feet of economizer ductwork, and over 2,000 tube welds. BMWC delivered the outage on time with a 1.59% weld reject rate.