MIDLAND - Construction work at the Midland Cogeneration Venture (MCV) Expansion is starting to power down after a summer-long project to install six new boilers at the 1,240-megawatt plant.

Later this month, the newly installed boilers at the plant will be available to be powered up, giving the MCV new, more energy-efficient options for operating during peak- and non-peak operating hours. The project is being managed by Monarch Welding and Engineering. Newkirk Electric and Pumford Construction are also involved.

"It's an impressive job," said Monarch Supt. John Sample "Realistically, we're doing a lot of work here in an accelerated time frame. "No complaints at all about the workforce, the people are responding well."

There are 13 existing natural gas-fired boilers at the plant, which have been in service for 18 years. They produce electricity to put on the electric grid through Consumers Energy, as well as steam for the nearby Dow Chemical Plant. The plant provides about 10 percent of Michigan's electrical capacity in the Lower Peninsula.

The six new natural gas units will be smaller than the original 13 - and having them in place will allow the plant to shut down the larger boilers during off-peak hours. Monarch, its subs and the building trades "are building the whole system," Sample said. "When we're finished, they will be able to run any of the smaller six boilers and turn off any of the other 13."

He said the new boilers are rated at 250,000 lbs. per hour of steam. Some 220 Hardhats have been working on the project, working two shifts, six-tens. Much of the fabrication work has taken place at Monarch's shop in nearby Monitor Twp. Meanwhile, the power plant has continued to operate, and Sample said he anticipates an easy tie-in with the new boilers.

The new boilers at the plant go hand-in-hand with a new agreement between the MCV, Consumers Energy and the Michigan Public Service Commission. According to the MPSC, due to higher natural gas prices, the MCV had become uneconomical to operate under its existing contract with Consumers Energy and the company was considering exercising its right to cancel the contract and sell the power on the open market, including to out-of-state purchasers.

On June 10, the MPSC announced approval of a plan that reduces Consumers Energy's fixed cost payment to the MCV in exchange for changes in operations - involving installation of the new boilers - that ensure that the plant only runs when it is economically advantageous to do so. The agreement will also allow Consumers Energy to buy electricity from the plant only when cheaper electricity is not available from alternative sources.

The agreement means the plant will continue to serve Michigan's needs for the remaining 17 years of the plant's contract life, and the MPSC estimates that the plan will save ratepayers more than $40 million per year.

The Midland Cogeneration Venture plant is getting six new boilers, thanks to the work of the building trades. Billy Collins (UA Local 85) and Joe Hunt (UA Local 174) assemble a control valve for the plant at the Monarch Welding and Engineering shop.