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Dallman 4 Construction
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Altogether, CWLP has 10 active generating units, consisting of four coal-fired steam turbine-generators, one dual-fuel (natural gas- and oil-fired) combustion turbine,  two oil-fired combustion turbines, and three diesel generators. The maximum summer net capability (nameplate rating) of all 10 units is 723 megawatts (MW). The largest and newest of these generating units is the 200-MW Dallman 4 coal-fired plant, which was commissioned in mid-November 2009.

Lakeside Power Station (Retired) (click to open)
The Lakeside Power Station was the original generating facility constructed in the mid-1930s on the shore of the utility's then-new man-made Lake Springfield. By the mid-1960s, Lakeside consisted of eight coal-fired boilers and seven turbine-generators. Two of these—boilers 7 and 8 and turbine units 6 and 7, which had a combined maximum capacity of 76 MW—remained active in meeting intermediate customer load until mid-2009. However, age and increasingly stringent emissions control requirements took their toll on the old Lakeside plant and, rather than spending the multi-millions of dollars that would be needed to bring the old units into compliance with state and federal standards, in 2002 the utility decided to construct a new, larger, state of the art, environmentally friendly power plant and, upon its completion, cease using the Lakeside units. The Dallman 4 Power Station went online in May 2009, at which time, Lakeside units 6 and 7 became non-operational.

Dallman Power Station (click to open)
The Dallman Power Station was built just to the southwest of the Lakeside Power Station in 1968 to answer the increasing electric demand of a growing city. It contains three coal-fired generating units. The Dallman 4 Power Station, which was built to the west of the original Dallman Station, was completed in 2009.

The first Dallman generator placed on line was Dallman 1, with a maximum nameplate capacity of 86 MW (most recently tested at 65 MW). It was followed by Dallman 2, with a nameplate rating of 87 MW (most recently tested at 62 MW), in 1972. In 1978, the completion of Dallman 3, which has a maximum nameplate capacity of 199 MW (most recently tested at 1871 MW), more than doubled the power station's total generating capacity. Dallman 4 has a maximum capacity of 200 MW (most recently tested at 208 MW) and provides the most cost-efficient energy of all of CWLP's generating units. (Read more about Dallman 4.) These four coal-fired units are intended to meet customer base load.

In 2014, the four Dallman generators used 1,251,473 tons of coal, 567,244 gallons of oil, and 519,580 dekatherms of natural gas, all of which cost $60,622,126.00 to generate 2,344,681.13 MWH of electricity. The net fuel cost of these generators was $25.86 per MWH.

Environmental Controls
All four Dallman units are designed to burn coal with an approximate heat content of 10,500 Btu per pound. Particulate emissions from all four units are controlled by electrostatic precipitators. In addition, Dallman 4 utilizes a fabric filter bag house to aid in particulate emission control. 

In addition, the four units are equipped with  flue gas desulfurization systems (scrubbers) to control sulfur dioxide (SO2) emissions. The use of scrubbing technology, which uses limestone to trap SO2 in the flue gas before it can be emitted into the atmosphere, allows CWLP to meet and exceed federal Clean Air Act requirements while continuing to use high-sulfur Illinois coal. The by-product from this process, synthetic gypsum, can be used as a soil amendment and in cement making. The scrubber for Dallman 3 was installed in 1980 and underwent a $30 million upgrade that was completed in the spring of 2012. As part of this upgrade, more modern system controls and efficient equipment were installed to allow the unit to continue to comply with Clean Air Act regulations. A second scrubber, serving Dallman 1 and 2, was put into operation in June 2001 in response to requirements of the 1990 Clean Air Act Amendments. Dallman 4's scrubber was built when the plant was constructed.

Each unit is also equipped with selective catalytic reduction (SCR) systems, which operate year-round to reduce nitrogen oxides (NOX) emissions to levels allowed by both state and federal clean air requirements. The SCRs for the first three Dallman units, which cost a total of $76 million to install, were placed on line in May 2003.

In addition to the environmental control equipment described above, Dallman 4, one of the cleanest coal-fired generating units in the nation, is equipped with a state-of-the-art cooling tower that eliminates the need to send high-temperature condenser cooling water back into Lake Springfield. The other three Dallman Power Station units use once-through condenser cooling water systems with water being obtained from Lake Springfield and discharged back into the lake.

Dallman 4 Power Station (click to open)

The Genesis of a Power Plant: Dallman 4—a pamphlet commemorating the history of the Dallman 4 project in words and pictures—is available free of charge while supplies last. Order yours or view it online.

Dallman 4, a 200-MW (most recently tested at 208 MW) pulverized coal power plant, is one of the cleanest coal-fired generating units in the nation. Its completion ensures the city of Springfield a cost-efficient, reliable and environmentally responsible source of electric power for the next several decades.

Construction was begun on the plant in late 2006. Although still in the testing phase, the plant became operational on May 11, 2009, when—under power of natural gas—it produced 13 MW of electricity as the unit was synchronized to the grid. As testing continued, the plant began operating using coal on June 1 of that year. Systems-testing was completed on November 19, at which time the general contractor, KBV Springfield Power Partners, handed over operating control of the plant to CWLP. In addition to being completed months ahead of its contract completion date, Dallman 4 came in under its projected $454.6 million budget, a feat virtually unheard of in the power industry.

Employing a Foster Wheeler pulverized coal boiler, the nameplate-rated 200-MW unit (which tested in 2014 at 208 MW) replaced 76 MW of old coal-fired technology—the utility's two remaining Lakeside turbine generators. Lakeside Units #6 and #7, CWLP's oldest still-operating turbine generators at the time, were placed into service in 1961 and 1965, respectively. These plants have been been decommissioned.

Dallman 4 employs a number of environmental control technologies, including:

1. low-NOx burners for the boiler; a selective catalytic reduction (SCR) system for additional NOx removal;
2. a fabric filter bag house to remove fine particulate;
3. a wet flue gas desulfurization unit (scrubber) for the removal of SO2; and
4. a wet electrostatic precipitator to remove acid mist and ultra-fine particulate from the
flue gas.

This equipment assists CWLP in its goal of becoming one of the most environmentally friendly primarily coal-fired electric utilities in the nation.

Air emission controls aren't the only way Dallman 4 complements the utility's efforts to protect and preserve the environment. By utilizing state-of-the-art cooling towers, CWLP is able to avoid discharging high-temperature cooling water from the plant into Lake Springfield.

KBV Springfield Power Partners served as general contractor for the construction project; Black & Veatch designed the plant, while Kiewit provided the construction; and Burns & McDonnell served as owner's engineer on behalf of CWLP.

Dallman 4 Fun Facts

1. The unit burned approximately 552,500 tons (1.4 billion pounds) of Illinois coal in 2014.
2. The demand for coal supports about 80 mining jobs in Illinois.
3. Approximately 40 permanent jobs were needed to support the long-term operation and maintenance of the facility.
4. In constructing the facility:
     - 644 pier foundations were drilled
     - 21,500 cubic yards of concrete were poured
     - 7,100 tons of steel were used
5. The 8.8-million-pound Unit 4 boiler is hung from the top of the building.
6. The facility has three coal silos, each of which hold 650 tons of coal.
7. One of the unit's environmental controls, a pulse jet fabric filter baghouse, contains over 6,600 26-foot-long bags that collect fine particulate from the flue gas.
8. At 440 feet in height, the Unit 4 chimney is the second tallest structure in Springfield. (The Unit 3 chimney is the tallest; the Units 1 and 2 chimney is third tallest; and the State Capitol is fourth.) Construction of the Unit 4 chimney required only 28 days, 3 hours.

More information about Dallman 4 can be found in the Dallman Power Station collapsible panel above.

Peaking Generators (click to open)
CWLP operates three peaking generators, two that are oil-burning and one that has dual-fuel operating capabilities. These units have a combined maximum nameplate capacity of 146 MW.

Together, in 2014, these peaking turbines used a total of 931,408 dekatherms of natural gas costing $496,413 and 210,142 gallons of fuel oil costing $555,016 to generate 9,258.1 MWH of electricity. The average net fuel cost to operate these units was $113.46 per MWH.

Diesel Generators (click to open)
CWLP owns three oil-fired diesel generators, with a combined capacity of 5 MW, that serve as a back-up electric supply for the utility.

In 2014, these units used a total of 2,020 gallons of diesel oil costing $6,183.75 to generate 20.95 MWH of electricity. The unit’s net fuel cost was $295.17 per MWH.

Links to more information about CWLP power plants and related topics can be found in the left-hand column of this page.


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