Photo montage of CWLP scenes with CWLP seal and link to CWLP home page. Click on words City Water, Light and Power to link to home page.

New Plant Construction Photo Gallery

A three D computer-generated artist's rendering of the Dallman Four Power Plant created during the plant's design stage.
An artist's rendering of the new plant, as it will look when completed.
 
An aerial photo of the CWLP Stevenson Drive Plant grounds taken in August 2006 showing where ground has been cleared for construction of the Dallman Four Power Plant. An aerial photo taken January 12, 2007, showing the Dallman Four construction site, with several cement trucks and a large yellow crane rising in the background.

August 2006. This photo shows the land clearing and other pre-construction work for the new plant that began several months earlier. The cleared area in the foreground of this photo indicates the new plant site. The Dallman 3 Power Station facilities are located just to the right of photo-center. Part of the dark-brick Lakeside Power Station, which will be retired when the new plant becomes operational, can be seen at the far left.
                                                                                                    Photo by Terry Farmer

January 12, 2007. An aerial view of the construction site.
                                                                          Photo by Terry Farmer
   
A photo taken in January 2007 showing a large yellow crane rising from the center of the Dallman Four construction site. A photo taken February 22, 2007, showing workers installing the first of several concrete footings for the boiler section of the plant.

January 2007. A 280-foot crane towers over the Dallman 4 construction site. This photo was taken from the Dallman 33 stack, looking west.

February 22, 2007. On this day, workers poured nearly 1,200 yards of concrete, requiring 133 truck deliveries. This project, which created the first boiler footing for the new plant, was the first of several foundation installations that would be required during the construction period.
   
An aerial photo taken March 1, 2007, showing how work is progessing on the laying of concrete for boiler building footings and the Dallman Four stack foundation. A large yellow crane rises from the site and the Dallman Power Station and Dallman Three scrubber can be seen in the background. An aerial photo taken April 25, 2007, showing more progress on the pouring of foundations for the boiler section, as well as the air quality control system. Additional work is also being done on the stack.

March 1, 2007. In this aerial photo, the rectangular grey cement area in the center of the construc-tion site, just right of the crane support leg, is the boiler footing that was poured on February 22. The rectangular area to the left of the crane leg is another section of the boiler foundation, which is expected to be poured on March 22. At the far right center of the photo, the dark grey circular area surrounded by a reddish-colored exterior is the foundation for the plant stack.
     The white building at top center is the Dallman 3 scrubber. The grayish-white material piled behind the scrubber is limestone, which is used to create the wet slurry that absorbs sulfur dioxide (SO2) from the Dallman 3 flue gas. The white material piled in front of the building is synthetic gypsum, a byproduct of the flue gas desulfurization process. CWLP markets this material to cement manufacturers and as an agricultural soil amendment.
                                                                                                                                                               Photo by Terry Farmer

April 25, 2007. In the foreground of this photo, which was taken looking north, work is just beginning on construction of the Dallman 4 stack. The white concrete area north of the stack is the foundation mat for the air quality control system (AQCS), while north of that are five sections of the boiler foundation. Concrete for the boiler foundation sections two and four had yet to be poured when this photo was taken. The tall black structure rising from the northern-most section (section one) of the boiler footing is one of the four side forms for large concrete columns that will support the turbine and generator.
                                                                                       Photo by Terry Farmer
   
A photo taken on the evening of May 6, 2007, showing how tall the stack has grown. Lights illuminate the area so work can continue around the clock. An American flag flies from the top of the stack. A photo taken on May 7, 2007, showing how quickly the stack has grown in less than 24 hours. A photo taken the evening of May 15, 2007, showing the freshly poured concrete of the last portion of the boiler section foundation. The lighting gives an eerie green cast to the still wet concrete.

May 6, 2007. Construction of the Dallman 4 stack is taking place at lightning speed. With crews work-ing around the clock, the tower is growing in height by an average of 17 inches an hour.

May 7, 2007. This photo, taken less than 24 hours later, shows how quickly the stack is growing. When this photo was taken, the stack stood 165 feet tall. On May 12, it was 257 feet tall; by 6 a.m. on May 15, it was 320 feet tall; and by 9 a.m. the following day, it stood at 330 feet. When completed, the stack will be 440 feet tall and 38 feet in dia-meter. Altogether, the outer "skin" will require 1,800 cubic yards of concrete and 270,000 pounds of reinforcing steel. The interior of the chimney will include 84,000 pounds of structural steel, ap-proximately 450 linear feet of 15-foot fiberglass-reinforced pipe, 6 grated plat-forms, one elevator, and a 450-foot safety ladder.

May 15, 2007. The final part (section two) of the Dallman 4 boiler footing is poured. Note the green hue of the freshly poured concrete.
     
This photo taken July 24, 2007 shows that, in just over two months since the building's foundation was completed, much of the structural steel frame work of the multi-story boiler section has been erected. Two immense cranes stand sentry on either side of the building. This photo, also taken July 24, 2007, is similar to the previous photograph, showing part of the boiler section framework, but also showing the steel frame of the bag house and its wall sections that are lying nearby on the ground waiting to be attached.

July 24, 2007. Erection of the structural steel skeleton of the main plant building, which will house the boiler and turbine, is well underway. The large open area in the center of the building is where the boiler will be located, while the upper-most section of the building will house the turbine. Just north of the structure, you can see the plant's steam condenser, which eventually will be lifted into its permanent place inside the building.

July 24, 2007. In the lower center of the photo, you can see the frame of the fabric filter bag house, located just south of the main plant building (seen in the upper-center of the photo). The dark orange objects at photo-left are the bag house walls, which are waiting to be attached to the steel frame. The bag house, one of the plant's state-of-the-art environmental control technologies, will remove fine particulates from the flue gas. The circular object at photo-right is the foundation of the absorber slurry holding tank for the Dallman 4 SO2 scrubber, which is yet to be built.
     From the first day of construction through July 25, 2007, KBV (the general con-struction contractor) installed approximately 1,300 tons of steel, 926 tons of rebar, and 9,700 yards of concrete.
   
This photo, taken August 23, 2007, shows the enormous red generator, strapped to the flat bed of a long transport truck just after crossing Spaulding Dam on its way to the Stevenson Drive plant complex. This photo taken February 28, shows the almost completed Dallman 4 stack, the completed steel frame of the building with sheet metal siding being attached, a portion of the Dallman Power Station and the Dallman 3 scrubber, the Dallman 31 and 32 and Dallman 33 stacks, and Lake Springfield in the background.

August 23, 2007. The Dallman 4 generator arrives at the plant site. Weighing approximately a half-million pounds (250 tons) and standing 28 feet long, 16 feet wide and 14 feet high, it is the largest piece of equipment brought on site for the new 200-MW facility. Trans-porting the generator to the plant required a 320-wheel rig that also weighed about 250 tons.

February 2008. Construction has come quite a long way since the first concrete foundation was poured just one year before. In the far lower left corner of  the building, you can see the first portions of the sheet metal siding being applied to the steel framing.
                                                                                  Photo by Terry Farmer
   
This ground-level photo of the plant, taken in February 2008, shows the steel framework and some steel sheeting that has been applied to one section. This photo, taken inside the plant in February 2008, shows huge red pipes, one angling downward and another, just behind, angling upward. A man standing on a catwalk next to the pipes is dwarfed by their massive size. This photo, taken inside the plant in February 2008, shows several stories of gray flooring supports and railings, behind, in front of and through which you can see numerous red pipes and other equipment.

February 2008. A ground-level view showing the beginning applica-tion of sheet metal siding to the steel framework (far right).

February 2008. The following three photos provide interior views of the plant. In this photo, the lower red pipe is the primary duct used to heat coal mills and transport  pulverized coal to the coal burners. It has a diameter of more than 8 feet. The upper red duct is the overfire air duct that provides additional combustion air to the boiler to ensure complete coal combustion. It has a diameter of 7.5 feet and is located approximately 81 feet (about 8 stories) above ground level.

February 2008. At the top center of this photo, you can see the end of the overfire air duct pictured in the previous photo. The red equipment pic-tured in the left half of the photo are five of the nine coal burners that will ultimately be installed. The gray pipes at the bottom left are coal conduits that will carry coal to the burners. The red pipe running vertically on the right side of the photo is called a "down corner." It will circulate hot water from the bottom to the top of the boiler.
     
In this photo, taken inside the plant building in February 2008, you are looking upward through several stories of gray structural steel supports at a red cylindrical shape suspended from the building's ceiling. The main focus of this photo, taken outside of the building in February 2008, is the pulse jet fabric filter bag house, a large burnt rectangular structure that has four funnel shaped objects descending from its bottom.
February 2008. The red piece of equipment at the top of the photo is the steam drum. It will separate water from steam in order to prepare it for use in the steam turbine. The steam drum is located 164 feet (about 16 stories) above ground level. February 2008. This photo depicts two important components of Dallman 4's environmental control system. The brownish-orange structure is the pulse jet fabric filter bag house. Over 6,600 filter bags enclosed inside this structure will remove dust and mercury from the boiler flue gas before the "smoke" is released into the air. Next, the flue gas will pass through the SO2 scrubber/absorber—the milk can-shaped structure pictured to the right of the bag house. (The upper portion of the scrubber/absorber is pictured in the next photo.) The purpose of the scrubber/absorber is to remove sulfur dioxide (SO2) from the flue gas. To the far right of this photo, you can see a portion of the Dallman 4 stack.
   
This photo, taken in February 2008, shows a large gray cylindrical structure that appears to be about five to six stories high. This photo, taken in February 2008, shows a large blue cylinder lying on its side next to a pick up truck. The cylinder is approximately twice as high and about one-and-a-half times as wide as the truck.

February 2008. This is the top portion of the SO2 scrubber/ab-sorber, which eventually will be lifted into position atop the milk can-shaped structure pictured in the previous photo. Once finished, the scrubber will be approximately 120 feet tall.

February 2008. This portion of the limestone ball mill holds steel balls that will crush rock limestone to a powdery consistency for use in the SO2 scrubber/absorber. The limestone powder will be mixed with water, forming a "slurry" that will be sprayed through the flue gas stream to remove sulfur dioxide (SO2).
   
This photo, taken in February 2008, shows four large, upright, side-by-side, metal cylindrical structures that are located right outside the new plant. The steel framework of the plant can be seen rising above the tops of the tanks. This photo, taken in February 2008, shows a large, rectangular steel framed structure with a shiny silver interior and cross bracing across the open face.

February 2008. These four tanks will hold various liquids required in the air quality control process. From left to right: (1) the limestone slurry storage tank, which is 32 feet in diameter and 34 feet tall and will hold 150,000 gallons; (2) the reclaim water tank, which is 33 feet in diameter and 35 feet tall and will hold 171,000 gallons; (3) the demineralizer water tank, which is 26 feet in diameter and 32 feet tall and will hold 127,000 gallons; and (4) the slurry holding tank, which is 50 feet in diameter and 52 feet tall and will hold 600,000 gallons.

February 2008. The electrostatic precipitator pictured here is the last environmental device through which Dallman 4 flue gas will pass before entering the stack for release into the atmosphere. The precipitator will collect acid mist and fine particulates that are not captured by the pulse jet fabric filters or the scrubber. Once in position between the top of the scrubber and the stack inlet, this 24-foot by 27-foot device will be located about 140 feet above ground level.
   
In this photo, taken July 31, 2008, what appears to be hundreds of purple, black, blue and yellow wires run through and into silver-colored metal bracing and conduit pipes. In this photo, taken July 31, 2008, two men in hard hats and neon green safety vests check out the Dallman Four control console, which consists of a desk top, numerous monitors, and a variety of buttons and red lights.

July 31, 2008. A small portion of the more than 1.7 million feet (nearly 325 miles) of electrical wire that run throughout the plant.

July 31, 2008. The Unit 4 control room, still under construction.
   
In this photo, taken July 31, 2008, three men stand on a scaffolding platform that encircles the top of a dark gray cylindrical tank as they weld another section of the tank's outer skin into place. A tall crane stands in the background. In this photo, taken July 31, 2008, two large bright green pipes extend horizontally out of the north end of the plant building and then bend downward, disappearing into the ground. A somewhat smaller green pipe comes extends out of west side of the building, then bends vertically to run parallel to the building wall and into the ground.

July 31, 2008. Workers weld together sections of the boron mitigation effluent tank. Part of the new plant's environmental control process will involve reducing the amount of boron, a byproduct of the coal com-bustion process, released into Sugar Creek from the ash pits.

July 31, 2008. This photo shows a view of the north side of the Unit 4 cooling tower. The green pipe on the far right brings circulating water into the tower. The green pipes on the left carry circulating water from the tower.
   
In this photo, taken July 31 2008, three enormous cylindrical tanks sit side-by-side on the ground, while a third, smaller tank, encased inside a steel framework, appears to sit above the middle tank. This photo, taken July 31, 2008, shows the structural steel framework of entire plant, including the air quality control section. The Dallman Four stack is seen on the left side of the image. From this vantage point, you can see that the smaller tank encased in a steel framework described in the previous photo, is not actually sitting on top of one of the lower tanks but is actually positioned within the framework of the Air Quality Control System building.

July 31, 2008. The ground level cylinders are three of the four tanks that will hold fluids needed for the air quality control system (see the February 2008 photo of the ACQS tanks). The steel frame structure rising behind is the air quality control system (AQCS) building. You can see the limestone slurry storage tank inside.

July 31, 2008. (a)The boiler building, still awaiting application of its steel siding. (b)The air quality control system building, also still awaiting cladding. (c)The electrostatic precipitator, which will remove fine particulates from the flue gas. (d)The 440-foot Dallman 4 stack.
   
In this aerial photo, taken September 1, 2008, you see the west side of the plant building with between one-quarter and one-half of its steel siding in place. Spaulding Dam, Lakeside Power Station and a small part of Lake Springfield are in the background. In this aerial photo, taken November 5, 2008, you see the west side of the plant building with significantly more of the siding and roofing in place, compared to the previous photo.

September 1, 2008. The progress made in applying finishes to the plant between September 1 and November 5, 2008 (next photo) can be seen in these two aerials.
                                                                                                Photo by Terry Farmer

 November 5, 2008.
                                                                                                 Photo by Terry Farmer
 
   
This aerial photo, taken January 8, 2009, shows the west side of the plant building with still more of the exterior work completed. This aerial photo, taken January 8, 2009, shows the east side of the plant building, on which the vast majority of the exterior work appears to be completed.
January 8, 2009.
                                                                                                                          Photo by Terry Farmer		 January 8, 2009.
                                                                                                            Photo by Terry Farmer
   
This aerial photo, taken February 5, 2009, provides a full view of the west side of the plant, including the stack and the cooling towers that are located on a point of land to the south of the plant. Steam billows from the Dallman 31 and 32 and Dallman 33 stacks, which rise behind the Dallman Four plant. In the middle background is the lake and in the far background is land, on which a neighborhood can be viewed beyond the leafless trees on the shoreline.
February 5, 2009. It won't be long until the still-pristine Dallman 4 stack (foreground) begins emitting steam alongside its Dallman Unit 33  (center) and Unit 31/32 counterparts. At photo right, the long grey structure jutting out into the lake houses the Dallman 4 cooling towers.
                                                                                                                                                     Photo by Terry Farmer
 
This aerial photo, taken April 3, 2009, looking from the west, gives a good view of most of the Stevenson Drive plant grounds, including the new Dallman Four Plant and stack, part of the Dallman Four cooling tower structure, the Dallman Power Station and stacks, the Lakeside Power Station, the Water Purification Plant and three of the five water clarifiers. Spaulding Dam and the lake are in the background.
April 3, 2009. The Stevenson Drive Plant complex just days before Dallman 4 (foreground) undergoes its first firing (using natural gas) and begins boiler steam-blow testing (see below). The Dallman 3 station is center right in this photo; the old Lakeside plant, which will be formally decommissioned once Unit 4 goes online, is the large red brick building in back center; and the Water Purification Plant is the long, low red brick building near the top left corner of Dallman 4.
                                                                                                                                                     Photo by Terry Farmer
 
This photo, taken April 14, 2009, shows a massive pillar of steam rising from a large vertical pipe.
April 14, 2009. Over the course of several days the new boiler underwent a series of "steam blows" to clean the boiler and boiler tubes and piping of built-up dust, welding slag and other debris that, if carried into the turbine by high-speed steam, could cause serious equipment damage. During the steam blows, the beginning boiler pressure was typically between 700 and 900 pounds per square inch (psi); the beginning boiler temperature was typically about 575 degrees F; the velocity of the steam through the pipes was about 5,800 feet per second (3,950 miles per hour); and up to about 12,000 pounds of steam per minute could be released. The steam blows, each of which lasted about 5 minutes, took place about every hour, 24 hours a day for 13 days.
 
This aerial photo, taken June 4, 2009, shows steam coming from the Dallman Four stack. In the foreground, you can see the Dallman Four cooling tower structure and the plant's several-story-high coal pile. In the background you can see the tree-filled Glen Aire subdivision and the Capital City Shopping Center.
June 4, 2009. Still in its testing phase, Dallman 4 is online generating electricity for Springfield customers and the grid.
                                                                                                                                                     Photo by Terry Farmer
 


Dallman 4

Last updated: 05/17/10